Polyethylene compositions having high dimensional stability and excellent processability for caps and closures

ABSTRACT

A dual reactor solution polymerization process gives high density polyethylene compositions containing a first ethylene copolymer and a second ethylene copolymer and which have high dimensional stability, excellent processability as well as good organoleptic properties and reasonable stress cracking resistance. The polyethylene compositions are suitable for compression molding or injection molding applications and are useful, for example, in the manufacture of caps and closures for bottles, and for example, in bottles containing non-pressurized liquids.

This application is a continuation-in-part of U.S. application Ser. No.14/098,634, filed on Dec. 6, 2013, which claims priority to and thebenefit of Canadian Application No. 2,798,854, filed Dec. 14, 2012.

The present invention relates to polyethylene compositions that areuseful in the manufacture of molded articles such as closures forbottles.

Polymer compositions useful for molding applications, for example, themanufacture of caps and closures for bottles are well known. Screwclosures for example, are typically made from polypropylene (PP) inorder to achieve the necessary cap strength, however, an inner linercomposed of a soft polymer is required to provide necessary sealproperties. Also a PP closure alone does not have good organolepticproperties, which is another reason to use a liner. The soft inner linercan be made from ethylene/vinyl acetate (EVA), polyvinyl chloride (PVC),butyl rubber or other suitable material. The two-part cap is costly, andsingle part constructions may reduce costs.

One-piece closures, such as screw caps, have more recently been madefrom polyethylene (PE) resins. To date the use of high density resin isrequired if the closures are to have sufficient stiffness, while goodflow properties combined with an ability to resist cracking over time(as measured by for example, environmental stress crack resistance(ESCR)) is also desirable. Further, closures should be rapidly producedwhile not suffering from anisotropic shrinkage when released from amold. Such closures, for example, screw cap closures for water and otherdrink bottles, should, even when produced in high turnover, consistentlysatisfy strict dimensional tolerances to provide a consistent fit andseal and to maintain product integrity. Polyethylene closures alone havebetter organoleptic properties than PP closures alone.

Polyethylene blends produced with conventional Ziegler-Natta or Phillipstype catalysts systems can be made having suitably high density and ESCRproperties, see for example, WO 00/71615 and U.S. Pat. No. 5,981,664.However, the use of conventional catalyst systems may producesignificant amounts of low molecular weight polymer chains having highcomonomer contents, which results in resins having non-idealorganoleptic properties.

Examples of high density multimodal polyethylene blends made usingconventional catalyst systems for the manufacture of caps or closuresare taught in U.S. Pat. Nos. 7,750,083; 7,750,082; 7,790,826; 8,044,160;and 8,129,472; U.S. Patent Applications 2007/0213468 and 2008/0287608,as well as, WO 2007/060007 and EP 2,017,302A1. Further high density,multimodal polyethylene blends made by employing conventionalZiegler-Natta catalysts are disclosed in U.S. Patent Applications2009/0198018; 2009/0203848; 2008/0221273; 2010/0084363 and 2012/0022214.

In contrast to traditional catalysts, the use of so called single sitecatalysts (such as “metallocene” and “constrained geometry” catalysts)provides resin having lower catalyst residues and improved organolepticproperties as taught by U.S. Pat. No. 6,806,338. The disclosed resinsare suitable for use in molded articles. Further resins comprisingmetallocene catalyzed components which are useful for moldingapplications are described in U.S. Pat. Nos. 7,022,770; 7,307,126;7,396,878; 7,396,881; and 7,700,708.

A monomodal polyethylene composition which is useful in the preparationof a screw closure has been made using a mixed metallocene catalystsystem as described in U.S. Pat. No. 8,039,569.

U.S. Patent Application 2011/0165357A1 discloses a blend of metallocenecatalyzed resins which is suitable for use in pressure resistant pipeapplications.

U.S. Patent Application 2006/0241256A1 teaches blends formulated frompolyethylenes made using a hafnocene catalyst in the slurry phase.

A bimodal resin having a relatively narrow molecular weight distributionand long chain branching is described in U.S. Pat. No. 7,868,106. Theresin is made using a bis-indenyl type metallocene catalyst in a dualslurry loop polymerization process and can be used to manufacture capsand closures.

U.S. Pat. No. 6,642,313 discloses multimodal polyethylene resins whichare suitable for use in the manufacture of pipes. A dual reactorsolution polymerization process is used to prepare the resins in thepresence of a phosphinimine catalyst.

Narrow molecular weight distribution polyethylene blends comprising ametallocene produced polyethylene component and a Zielger-Natta ormetallocene produced polyethylene component are reported in U.S. Pat.No. 7,250,474. The blends can be used in blow molding and injectionmolding applications such as for example, milk bottles and bottle capsrespectively.

For further references describing relevant polyethylene compositionssee: U.S. Pat. Nos. 7,875,690; 6,545,093; 8,129,489; 6,063,871;5,382,630; 5,382,631; 7,928,051; 6,809,154; 7,592,395; 6,194,520;5,858,491; 6,946,521; and 5,494,965 as well as U.S. Patent Application2010/0121006 and 2011/0136983.

In U.S. Pat. No. 8,022,143 we disclosed a resin composition having agood balance of toughness, ESCR, processability, and organolepticproperties for use in the manufacture of caps and closures. The resinswere made using a single site catalyst system in a dual reactor solutionpolymerization process, to provide bimodal polyethylene compositions inwhich comonomer was present in both a high and a low molecular weightcomponent. The disclosed resins had a normal comonomer distribution inthat the low molecular weight component had a larger amount of comonomerthan did the high molecular weight component.

In CA Patent Application 2,752,407 we disclosed resins having improvedESCR, good organoleptic properties, balanced rheological and mechanicalproperties and which were suitable for use in the manufacture of moldedarticles such as closures for bottles.

One embodiment of this invention provides single-site catalyzeddual-reactor resin composition which has high dimensional stability,excellent processability and organoleptic properties as well asreasonable stress cracking resistance. The new compositions have abetter isotropic shrinkage ratio (i.e. one which is closer to unity), alower shrinkage differential between TD and MD directions (i.e. closerto zero) and better processability in the extrusion shear rate range(i.e. lower melt viscosity) compared to the resins disclosed in U.S.Pat. No. 8,022,143 and CA Patent Application 2,752,407. The presentresins are especially suitable for use in the manufacture of caps andclosures for bottles containing water or other non-carbonated beverages.

One embodiment of this invention provides a polyethylene compositionthat can be used in the manufacture of caps and closures for bottles.

One embodiment of this invention provides resins for use in themanufacture of caps and closures for bottles containing water or othernon-carbonated beverages.

One embodiment of this invention provides a polyethylene compositionwhich has good dimensional stability while maintaining low shearviscosity values at high shear rates which is desirable for high-speedinjection applications.

One embodiment of this invention provides caps and closures comprising apolyethylene composition made by a two reactor solution phasepolymerization process and a single site catalyst. Molded disks madefrom the polyethylene compositions have good dimensional stability.

One embodiment of this invention is a closure for bottles, the closurecomprising a polyethylene composition, the polyethylene compositioncomprising:

(1) about 10 to about 70 wt % of a first ethylene copolymer having amelt index I₂, of from 0.1 to 10 g/10 min; a molecular weightdistribution M_(w)/M_(n), of less than 3.0; and a density of from 0.930to 0.960 g/cm³; and

(2) about 90 to about 30 wt % of a second ethylene copolymer having amelt index I₂, of from 50 to 10,000 g/10 min; a molecular weightdistribution M_(w)/M_(n), of less than 3.0; and a density higher thanthe density of the first ethylene copolymer, but less than 0.966 g/cm³;

wherein the density of the second ethylene copolymer is less than 0.037g/cm³ higher than the density of the first ethylene copolymer; the ratio(SCB1/SCB2) of the number of short chain branches per thousand carbonatoms in the first ethylene copolymer (SCB1) to the number of shortchain branches per thousand carbon atoms in the second ethylenecopolymer (SCB2) is greater than 1.0; and wherein the polyethylenecomposition has a molecular weight distribution M_(w)/M_(n), of from 2to 7; a density of at least 0.950 g/cm³; a high load melt index I₂₁, offrom 150 to 400 g/10 min; a Z-average molecular weight M_(Z), of lessthan about 300,000; a melt flow ratio I₂₁/I₂, of from 22 to 50; a stressexponent of less than 1.40; and an ESCR Condition B (100% IGEPAL) of atleast about 3.5 hrs; and

wherein the closure is a hinged closure.

One embodiment of this invention provides a closure for bottles, theclosure comprising a polyethylene composition, the polyethylenecomposition comprising:

(1) about 10 to about 70 wt % of a first ethylene copolymer having amelt index I₂, of from 0.1 to 10 g/10 min; a molecular weightdistribution M_(w)/M_(n), of less than 3.0; and a density of from 0.930to 0.960 g/cm³; and

(2) about 90 to about 30 wt % of a second ethylene copolymer having amelt index I₂, of from 50 to 10,000 g/10 min; a molecular weightdistribution M_(w)/M_(n), of less than 3.0; and a density higher thanthe density of the first ethylene copolymer, but less than 0.966 g/cm³;wherein the density of the second ethylene copolymer is less than 0.037g/cm³ higher than the density of the first ethylene copolymer; the ratio(SCB1/SCB2) of the number of short chain branches per thousand carbonatoms in the first ethylene copolymer (SCB1) to the number of shortchain branches per thousand carbon atoms in the second ethylenecopolymer (SCB2) is greater than 1.0; and wherein the polyethylenecomposition has a molecular weight distribution M_(w)/M_(n), of from 2to 7; a density of at least 0.950 g/cm³; a high load melt index I₂₁, offrom 150 to 400 g/10 min; a Z-average molecular weight M_(Z), of lessthan about 300,000; a melt flow ratio I₂₁/I₂, of from 22 to 50; a stressexponent of less than 1.40; and an ESCR Condition B (100% IGEPAL) of atleast about 3.5 hrs.

In an embodiment of the invention, the closure is made by compressionmolding.

In an embodiment of the invention, the closure is made by injectionmolding.

In an embodiment of the invention, the closure is a screw cap.

In an embodiment of the invention, the closure is a hinged closure.

One embodiment of this invention provides a polyethylene compositioncomprising:

(1) about 10 to about 70 wt % of a first ethylene copolymer having amelt index I₂, of from 0.1 to 10 g/10 min; a molecular weightdistribution M_(w)/M_(n), of less than 2.5; a composition distributionbreadth index (CDBI(50)) of greater than 65%; and a density of from0.930 to 0.960 g/cm³; and

(2) about 90 to about 30 wt % of a second ethylene copolymer having amelt index I₂, of from 50 to 10,000 g/10 min; a molecular weightdistribution M_(w)/M_(n), of less than 2.5; a composition distributionbreadth index (CDBI(50)) of greater than about 65%; and a density higherthan the density of the first ethylene copolymer, but less than 0.966g/cm³; wherein the density of the second ethylene copolymer is less than0.037 g/cm³ higher than the density of the first ethylene copolymer; theratio (SCB1/SCB2) of the number of short chain branches per thousandcarbon atoms in the first ethylene copolymer (SCB1) to the number ofshort chain branches per thousand carbon atoms in the second ethylenecopolymer (SCB2) is greater than 1.0; and wherein the polyethylenecomposition has a molecular weight distribution M_(w)/M_(n), of from 2to 7; a density of at least 0.950 g/cm³; a high load melt index I₂₁, offrom 150 to 400 g/10 min; a Z-average molecular weight M_(Z), of lessthan about 300,000; a melt flow ratio I₂₁/I₂, of from 22 to 50; a stressexponent of less than 1.40; and an ESCR Condition B (100% IGEPAL) of atleast about 3.5 hrs.

One embodiment of this invention provides a polyethylene compositioncomprising:

(1) about 10 to about 70 wt % of a first ethylene copolymer having amelt index I₂, of from 0.1 to 10 g/10 min; a molecular weightdistribution M_(w)/M_(n), of less than 2.5; and a density of from 0.930to 0.960 g/cm³; and

(2) 9 about 0 to about 30 wt % of a second ethylene copolymer having amelt index I₂, of from 50 to 10,000 g/10 min; a molecular weightdistribution M_(w)/M_(n), of less than 2.5; and a density higher thanthe density of the first ethylene copolymer, but less than 0.966 g/cm³;wherein the density of the second ethylene copolymer is less than 0.037g/cm³ higher than the density of the first ethylene copolymer; the ratio(SCB1/SCB2) of the number of short chain branches per thousand carbonatoms in the first ethylene copolymer (SCB1) to the number of shortchain branches per thousand carbon atoms in the second ethylenecopolymer (SCB2) is greater than 1.0; and wherein the polyethylenecomposition has a molecular weight distribution M_(w)/M_(n), of from 2to 7; a density of at least 0.950 g/cm³; a high load melt index I₂₁, offrom 150 to 400 g/10 min; a Z-average molecular weight M_(z), of lessthan 300,000; a melt flow ratio I₂₁/I₂, of from 22 to 50; a stressexponent of less than 1.40; and an ESCR Condition B (100% IGEPAL) of atleast about 3.5 hrs.

In an embodiment of the invention, the polyethylene composition has anESCR Condition B (100% IGEPAL) of from about 3.5 to about 15 hrs.

In an embodiment of the invention, the polyethylene composition has aTD/MD shrinkage ratio of from about 0.90 to about 1.15 when measuredaccording to the Dimensional Stability Test (DST).

In an embodiment of the invention, the polyethylene composition has amelt index I₂, of greater than 5.0 to less than 20 g/10 min.

In an embodiment of the invention, the first and second ethylenecopolymers are made by polymerizing ethylene and an alpha olefin in thepresence of a single site catalyst.

In an embodiment of the invention, the density of the second ethylenecopolymer is less than 0.030 g/cm³ higher than the density of the firstethylene copolymer.

In an embodiment of the invention, the first ethylene copolymer has amelt index I₂, of from 0.1 to 3.0 g/10 min.

In an embodiment of the invention, the second ethylene copolymer has amelt index I₂, of from 100 to 5000 g/10 min.

In an embodiment of the invention, the polyethylene composition has amelt index I₂, of from 6 to 12 g/10 min.

In an embodiment of the invention, the polyethylene composition has abimodal molecular weight distribution as determined by gel permeationchromatography.

In an embodiment of the invention, the ratio (SCB1/SCB2) of the numberof short chain branches per thousand carbon atoms in the first ethylenecopolymer (SCB1) to the number of short chain branches per thousandcarbon atoms in the second ethylene copolymer (SCB2) is at least 1.5.

In an embodiment of the invention, the polyethylene composition has amolecular weight distribution M_(w)/M_(n), of from 3.5 to 6.

In an embodiment of the invention, the first ethylene copolymer has adensity of from 0.936 to 0.952 g/cm³.

In an embodiment of the invention, the second ethylene copolymer has adensity of less than 0.965 g/cm³.

In an embodiment of the invention, the polyethylene composition has adensity of from 0.952 to 0.960 g/cm³.

In an embodiment of the invention, the polyethylene composition has nolong chain branching.

In an embodiment of the invention, the polyethylene composition has acomposition distribution breadth index (CDBI(50)) of greater than about65%.

In an embodiment of the invention, the polyethylene composition has acomposition distribution breadth index (CDBI(50)) of greater than about70%.

In an embodiment of the invention, the first and second ethylenecopolymers each have a composition distribution breadth index (CDBI(50))of greater than about 65%.

In an embodiment of the invention, the polyethylene compositioncomprises: from 25 to 60 wt % of the first ethylene copolymer; and from75 to 40 wt % of the second ethylene copolymer.

In an embodiment of the invention, the polyethylene composition has acomonomer content of less than about 0.5 mol % as determined by ¹³C NMR.

In an embodiment of the invention, the polyethylene composition furthercomprises a nucleating agent.

In an embodiment of the invention, the first and second ethylenecopolymers are copolymers of ethylene and 1-octene.

One embodiment of this invention provides a process to prepare apolyethylene composition, the polyethylene composition comprising:

(1) about 10 to about 70 wt % of a first ethylene copolymer having amelt index I₂, of from 0.1 to 10 g/10 min; a molecular weightdistribution M_(w)/M_(n), of less than 3.0; and a density of from 0.930to 0.960 g/cm³; and

(2) about 90 to about 30 wt % of a second ethylene copolymer having amelt index I₂, of from 50 to 10,000 g/10 min; a molecular weightdistribution M_(w)/M_(n), of less than 3.0; and a density higher thanthe density of the first ethylene copolymer, but less than 0.966 g/cm³;

wherein the density of the second ethylene copolymer is less than 0.037g/cm³ higher than the density of the first ethylene copolymer; the ratio(SCB1/SCB2) of the number of short chain branches per thousand carbonatoms in the first ethylene copolymer (SCB1) to the number of shortchain branches per thousand carbon atoms in the second ethylenecopolymer (SCB2) is greater than 1.0; and wherein the polyethylenecomposition has a molecular weight distribution M_(w)/M_(n), of from 2to 7; a density of at least 0.950 g/cm³; a high load melt index I₂₁, offrom 150 to 400 g/10 min; a Z-average molecular weight M_(Z), of lessthan about 300,000; a melt flow ratio I₂₁/I₂, of from 22 to 50; a stressexponent of less than 1.40; and an ESCR Condition B (100% IGEPAL) of atleast about 3.5 hrs.; the process comprising contacting at least onesingle site polymerization catalyst system with ethylene and at leastone alpha-olefin under solution polymerization conditions in at leasttwo polymerization reactors.

In an embodiment of the invention, the at least two polymerizationreactors comprise a first reactor and a second reactor configured inseries.

In an embodiment of the invention, the at least one alpha-olefin is fedexclusively to the first reactor.

One embodiment of the invention is a process for preparing a closure forbottles wherein the process comprises at least one compression moldingor injection molding step and wherein the closure comprises apolyethylene composition, the polyethylene composition comprising:

(1) about 10 to about 70 wt % of a first ethylene copolymer having amelt index I₂, of from 0.1 to 10 g/10 min; a molecular weightdistribution M_(w)/M_(n), of less than 3.0; and a density of from 0.930to 0.960 g/cm³; and

(2) about 90 to about 30 wt % of a second ethylene copolymer having amelt index I₂, of from 50 to 10,000 g/10 min; a molecular weightdistribution M_(w)/M_(n), of less than 3.0; and a density higher thanthe density of the first ethylene copolymer, but less than 0.966 g/cm³;

wherein the density of the second ethylene copolymer is less than 0.037g/cm³ higher than the density of the first ethylene copolymer; the ratio(SCB1/SCB2) of the number of short chain branches per thousand carbonatoms in the first ethylene copolymer (SCB1) to the number of shortchain branches per thousand carbon atoms in the second ethylenecopolymer (SCB2) is greater than 1.0; and wherein the polyethylenecomposition has a molecular weight distribution M_(w)/M_(n), of from 2to 7; a density of at least 0.950 g/cm³; a high load melt index I₂₁, offrom 150 to 400 g/10 min; a Z-average molecular weight M_(Z), of lessthan about 300,000; a melt flow ratio I₂₁/I₂, of from 22 to 50; a stressexponent of less than 1.40; and an ESCR Condition B (100% IGEPAL) of atleast about 3.5 hrs; and

wherein the closure is a hinged closure.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows the balance of processability and ESCR for variousinventive resins of the present invention and for some comparativeresins as demonstrated by a plot of the processability indicator (100/ηat 10⁵ s⁻¹ and 240° C.) against the ESCR B100. The inventive resins maybe used in caps and closures manufacture.

FIG. 2 shows the balance of processability and impact strength forvarious inventive resins of the present invention and for somecomparative resins as demonstrated by a plot of the Notched Izod ImpactStrength (J/m) against the processability indicator (100/η at 10⁵ s⁻¹and 240° C.). The inventive resins may be used for application in capsand closures manufacture.

FIG. 3 shows a graph of the dimensional stability of various inventiveresins of the present invention and for some comparative resins, wheredimensional stability is demonstrated by a plot of the TD/MD shrinkageratio (for an injection molded disk of circular shape) againstpost-molding time (in hours).

FIGS. 4A and 4B show the TREF profile of an inventive resin (4A) and acomparative resin (4B) where each is made with a single site catalyst bysolution polymerization. The inventive resin (4A) has a CDBI(50) ofgreater than about 70 wt % and may be used in the manufacture of capsand closures. The comparative resin (4B) has a CDBI(50) of less thanabout 50 wt %.

The present disclosure is related to caps and closures for bottles andto the polyethylene compositions and processes used to manufacture them.The polyethylene compositions are composed of at least two ethylenecopolymer components: a first ethylene copolymer and a second ethylenecopolymer. The polyethylene compositions of the invention have gooddimensional stability and are ideal materials for use in manufacturingcaps and closures for bottles containing non-carbonated soft drinks.

Notwithstanding that the numerical ranges and parameters setting forththe broad scope of the invention are approximations, the numericalvalues set forth in the specific examples are reported as precisely aspossible. Any numerical values, however, inherently contain certainerrors necessarily resulting from the standard deviation found in theirrespective testing measurements.

Also, it should be understood that any numerical range recited herein isintended to include all sub-ranges subsumed therein. For example, arange of “1 to 10” is intended to include all sub-ranges between andincluding the recited minimum value of 1 and the recited maximum valueof 10; that is, having a minimum value equal to or greater than 1 and amaximum value of equal to or less than 10. Because the disclosednumerical ranges are continuous, they include every value between theminimum and maximum values. Unless expressly indicated otherwise, thevarious numerical ranges specified in this application areapproximations.

All compositional ranges expressed herein are limited in total to and donot exceed 100 percent (volume percent or weight percent) in practice.Where multiple components can be present in a composition, the sum ofthe maximum amounts of each component can exceed 100 percent, with theunderstanding that, and as those skilled in the art readily understand,that the amounts of the components actually used will conform to themaximum of 100 percent.

The terms “cap” and “closure” are used interchangeably in the currentinvention, and both connote any suitably shaped molded article forenclosing, sealing, closing or covering etc., a suitably shaped opening,a suitably molded aperture, an open necked structure or the like used incombination with a container, a bottle, a jar and the like.

It is well known that metallocene catalysts and other so called “singlesite catalysts” generally incorporate comonomer more evenly thantraditional Ziegler-Natta catalysts when used for catalytic ethylenecopolymerization with alpha olefins. This fact is often demonstrated bymeasuring the composition distribution breadth index (CDBI) forcorresponding ethylene copolymers. The composition distribution of apolymer can be characterized by the short chain distribution index(SCDI) or composition distribution breadth index (CDBI). The definitionof composition distribution breadth index (CDBI(50)) can be found in PCTpublication WO 93/03093 and U.S. Pat. No. 5,206,075. The CDBI(50) isconveniently determined using techniques which isolate polymer fractionsbased on their solubility (and hence their comonomer content). Forexample, temperature rising elution fractionation (TREF) as described byWild et al. J. Poly. Sci., Poly. Phys. Ed. Vol. 20, p 441, 1982 or inU.S. Pat. No. 4,798,081 can be employed. From the weight fraction versuscomposition distribution curve, the CDBI(50) is determined byestablishing the weight percentage of a copolymer sample that has acomonomer content within 50% of the median comonomer content on eachside of the median. Alternatively, the CDBI(25), which is sometimes usedin the art, is determined by establishing the weight percentage of acopolymer sample that has a comonomer content within 25% of the mediancomonomer content on each side of the median.

The First Ethylene Copolymer

The first ethylene copolymer of the polyethylene composition of thecurrent invention has a density of from about 0.930 g/cm³ to about 0.960g/cm³; a melt index, I₂, of more than 0.1 g/10 min; a molecular weightdistribution, M_(w)/M_(n), of below about 3.0 and a weight averagemolecular weight M_(w), that is greater than the M_(w) of the secondethylene copolymer. In one embodiment, the weight average molecularweight M_(w), of the first ethylene copolymer is at least 50,000 g/mol.

By the term “ethylene copolymer” it is meant that the copolymercomprises both polymerized ethylene and at least one polymerizedalpha-olefin comonomer, with polymerized ethylene being the majorityspecies.

In an embodiment of the invention, the first ethylene copolymer is madewith a single site catalyst, such as, for example, a phosphiniminecatalyst.

The comonomer (i.e., alpha-olefin) content in the first ethylenecopolymer can be from about 0.05 to about 3.0 mol % as measured by ¹³CNMR, or FTIR or GPC-FTIR methods, or as calculated from a reactor model(see the Examples section). The comonomer is one or more suitable alphaolefin, which include, but are not limited to, 1-butene, 1-hexene,1-octene and the like. In one embodiment the alpha olefin is 1-octene.

The short chain branching in the first ethylene copolymer can be fromabout 0.25 to about 15 short chain branches per thousand carbon atoms(SCB1/1000Cs). In further embodiments of the invention, the short chainbranching in the first ethylene copolymer can be from 0.25 to 10, orfrom 0.25 to 7.5, or from 0.25 to 5, or from 0.25 to 3 branches perthousand carbon atoms (SCB1/1000Cs). The short chain branching is thebranching due to the presence of alpha-olefin comonomer in the ethylenecopolymer and will for example have two carbon atoms for a 1-butenecomonomer, or four carbon atoms for a 1-hexene comonomer, or six carbonatoms for a 1-octene comonomer, etc. The comonomer is one or moresuitable alpha-olefin, which include, but are not limited to, 1-butene,1-hexene, 1-octene and the like. In one embodiment the alpha olefin is1-octene.

In an embodiment of the invention, the comonomer content in the firstethylene copolymer is greater than comonomer content of the secondethylene copolymer (as reported, for example, in mol %).

In an embodiment of the invention, the amount of short chain branchingin the first ethylene copolymer is greater than the amount of shortchain branching in the second ethylene copolymer (as reported in shortchain branches, SCB per thousand carbons in the polymer backbone,1000Cs).

In some embodiments of the invention the melt index, I₂, of the firstethylene copolymer can be from 0.1 to 10 g/10 min and including narrowerranges within this range and any numbers encompassed by these ranges.For example, the melt index I₂ of the first ethylene composition can befrom above 0.1 to below 10 g/10 min, or can be from 0.1 to 7.5 g/10 min,or from 0.1 to 5.0 g/10 min, or from 0.1 to 3.0 g/10 min, or from 0.1 to2.5 g/10 min, or from 0.1 to 1.0 g/10 min.

In an embodiment of the invention, the first ethylene copolymer has aweight average molecular weight M_(w) of from about 50,000 to about225,000 g/mol including narrower ranges and any numbers encompassed bythese ranges. For example, in another embodiment of the invention, thefirst ethylene copolymer has a weight average molecular weight M_(w) offrom about 75,000 to about 200,000. In further embodiments of theinvention, the first ethylene copolymer has a weight average molecularweight M_(w) of from about 75,000 to about 175,000, or from about 85,000to about 150,000, or from about 100,000 to about 150,000.

The density of the first ethylene copolymer is in the present inventionfrom 0.930 to 0.960 g/cm³ or can be a narrower range within this rangeand any numbers encompassed by these ranges. For example, in furtherembodiments of the invention, the density of the first ethylenecopolymer can be from 0.936 to 0.960 g/cm³, or can be from 0.938 to0.960 g/cm³, or from 0.936 to 0.952 g/cm³, or from 0.938 to 0.952 g/cm³,or from 0.936 to 0.950 g/cm³, or from 0.938 to 0.950 g/cm³, or from0.936 to 0.947 g/cm³, or from 0.938 to 0.947 g/cm³, or from 0.936 to0.945 g/cm³, or from 0.938 to 0.945 g/cm³.

In embodiments of the invention, the first ethylene copolymer has amolecular weight distribution M_(w)/M_(n) of <3.0, or ≦2.7, or <2.7, or≦2.5, or <2.5, or ≦2.3, or from 0.8 to 2.3.

In an embodiment of the invention, the first ethylene copolymer of thepolyethylene composition is produced with a single site catalyst and hasa weight average molecular weight M_(w), of at least 50,000 g/mol; amolecular weight distribution, M_(w)/M_(n), of less than 3.0 and adensity of from 0.936 to 0.950 g/cm³.

In an embodiment of the invention, a single site catalyst is used andthe ethylene copolymer has a CDBI(50) of at least about 65% by weight,or at least about 70%, or at least about 75%, or at least about 80%, orat least about 85%, during solution phase polymerization in a singlereactor, is used in the preparation of the first ethylene copolymer.

In an embodiment of the present invention, the first ethylene copolymeris ethylene copolymer which has a CDBI(50) of greater than about 60% byweight, or greater than about 65%, or greater than about 70%, or greaterthan about 75%, or greater than about 80%, or greater than about 85%.

The first ethylene copolymer can comprise from about 10 to about 70weight percent (wt %) of the total weight of the first and secondethylene copolymers. In an embodiment of the invention, the firstethylene copolymer comprises from 20 to about 60 weight percent (wt %)of the total weight of the first and second ethylene copolymers. In anembodiment of the invention, the first ethylene copolymer comprises fromabout 25 to about 60 weight percent (wt %) of the total weight of thefirst and second ethylene copolymers. In an embodiment of the invention,the first ethylene copolymer comprises from about 30 to about 60 weightpercent (wt %) of the total weight of the first and second ethylenecopolymers. In an embodiment of the invention, the first ethylenecopolymer comprises from about 40 to about 50 weight percent (wt %) ofthe total weight of the first and second ethylene copolymers.

The Second Ethylene Copolymer

The second ethylene copolymer of the polyethylene composition of thecurrent invention has a density below 0.967 g/cm³ but which is higherthan the density of the first ethylene copolymer; a melt index I₂, offrom about 50 to 10,000 g/10 min; a molecular weight distribution,M_(w)/M_(n), of below about 3.0 and a weight average molecular weightM_(w) that is less than the M_(w) of the first ethylene copolymer. Inone embodiment, the weight average molecular weight, M_(w) of the secondethylene copolymer will be below 45,000 g/mole.

In an embodiment of the invention, the second ethylene copolymer is madewith a single site catalyst, such as for example a phosphiniminecatalyst.

The comonomer content in the second ethylene copolymer can be from about0.05 to about 3 mol % as measured by ¹³C NMR, or FTIR or GPC-FTIRmethods, or as calculated from a reactor model (see Examples section).The comonomer is one or more suitable alpha olefins, which include, butare not limited to, 1-butene, 1-hexene, 1-octene and the like. In oneembodiment the alpha olefin is 1-octene.

The short chain branching in the second ethylene copolymer can be fromabout 0.25 to about 15 short chain branches per thousand carbon atoms(SCB1/1000Cs). In further embodiments of the invention, the short chainbranching in the first ethylene copolymer can be from 0.25 to 10, orfrom 0.25 to 7.5, or from 0.25 to 5, or from 0.25 to 3 branches perthousand carbon atoms (SCB1/1000Cs). The short chain branching is thebranching due to the presence of alpha-olefin comonomer in the ethylenecopolymer and will for example have two carbon atoms for a 1-butenecomonomer, or four carbon atoms for a 1-hexene comonomer, or six carbonatoms for a 1-octene comonomer, etc. The comonomer is one or moresuitable alpha olefin. Examples of alpha olefins include, but are notlimited to 1-butene, 1-hexene, 1-octene and the like. In one embodimentthe alpha olefin is 1-octene.

In an embodiment of the invention, the comonomer content in the secondethylene copolymer is less than the comonomer content of the firstethylene copolymer (as reported for example in mol %).

In an embodiment of the invention, the amount of short chain branchingin the second ethylene copolymer is less than the amount of short chainbranching in the first ethylene copolymer (as reported in short chainbranches, SCB per thousand carbons in the polymer backbone, 1000Cs).

In the present invention, the density of the second ethylene copolymeris less than 0.967 g/cm³. In another embodiment of the invention, thedensity of the second ethylene copolymer is less than 0.966 g/cm³. Inanother embodiment of the invention, the density of the second ethylenecopolymer is less than 0.965 g/cm³. In another embodiment of theinvention, the density of the second ethylene copolymer is less than0.964 g/cm³. In an embodiment of the invention, the density of thesecond ethylene copolymer is from 0.952 to 0.967 g/cm³ or can be anarrower range within this range, including all the number encompassedwithin these ranges.

In the present invention, the second ethylene copolymer has a densitywhich is higher than the density of the first ethylene copolymer, butless than about 0.037 g/cm³ higher than the density of the firstethylene copolymer. In an embodiment of the invention, the secondethylene copolymer has a density which is higher than the density of thefirst ethylene copolymer, but less than about 0.035 g/cm³ higher thanthe density of the first ethylene copolymer. In another embodiment ofthe invention, the second ethylene copolymer has a density which ishigher than the density of the first ethylene copolymer, but less thanabout 0.030 g/cm³ higher than the density of the first ethylenecopolymer. In still another embodiment of the invention, the secondethylene copolymer has a density which is higher than the density of thefirst ethylene copolymer, but less than about 0.027 g/cm³ higher thanthe density of the first ethylene copolymer. In still another embodimentof the invention, the second ethylene copolymer has a density which ishigher than the density of the first ethylene copolymer, but less thanabout 0.025 g/cm³ higher than the density of the first ethylenecopolymer.

In an embodiment of the invention, the second ethylene copolymer has aweight average molecular weight M_(w) of less than 45,000 g/mol. Inanother embodiment of the invention, the second ethylene copolymer has aweight average molecular weight M_(w) of from about 7,500 to about40,000. In further embodiments of the invention, the second ethylenecopolymer has a weight average molecular weight M_(w) of from about9,000 to about 35,000, or from about 10,000 to about 30,000, or fromabout 10,000 to 25,000.

In embodiments of the invention, the second ethylene copolymer has amolecular weight distribution (M_(w)/M_(n)) of <3.0, or ≦2.7, or <2.7,or ≦2.5, or <2.5, or ≦2.3, or from 1.8 to 2.3.

In an embodiment of the invention, the melt index I₂ of the secondethylene copolymer can be from 50 to 10,000 g/10 min. In anotherembodiment of the invention, the melt index I₂ of the second ethylenecopolymer can be from 100 to 5,000 g/10 min. In another embodiment ofthe invention, the melt index I₂ of the second ethylene copolymer can befrom 50 to 3,500 g/10 min. In another embodiment of the invention, themelt index I₂ of the second ethylene copolymer can be from 100 to 10,000g/10 min. In yet another embodiment of the invention, the melt index I₂of the second ethylene copolymer can be from 1000 to 7000 g/10 min. Inyet another embodiment of the invention, the melt index I₂ of the secondethylene copolymer can be from 1200 to 10,000 g/10 min. In yet anotherembodiment of the invention, the melt index I₂ of the second ethylenecopolymer can be from 1200 to 7,000 g/10 min. In yet another embodimentof the invention, the melt index I₂ of the second ethylene copolymer canbe greater than 1200, but less than 5000 g/10 min. In still yet anotherembodiment of the invention, the melt index I₂ of the second ethylenecopolymer can be greater than 1000, but less than 3000 g/10 min. Instill yet another embodiment of the invention, the melt index I₂ of thesecond ethylene copolymer can be greater than 500, but less than 3000g/10 min. In still yet another embodiment of the invention, the meltindex I₂ of the second ethylene copolymer can be greater than 250, butless than 2700 g/10 min. In still yet another embodiment of theinvention, the melt index I₂ of the second ethylene copolymer can begreater than 150, but less than 2700 g/10 min.

In an embodiment of the invention, the melt index I₂ of the secondethylene copolymer is greater than 100 g/10 min. In an embodiment of theinvention, the melt index I₂ of the second ethylene copolymer is greaterthan 200 g/10 min. In an embodiment of the invention, the melt index I₂of the second ethylene copolymer is greater than 500 g/10 min. In anembodiment of the invention, the melt index I₂ of the second ethylenecopolymer is greater than 1000 g/10 min. In an embodiment of theinvention, the melt index I₂ of the second ethylene copolymer is greaterthan 1200 g/10 min. In an embodiment of the invention, the melt index I₂of the second ethylene copolymer is greater than 1500 g/10 min.

In an embodiment of the invention, the second ethylene copolymer of thepolyethylene composition is made with a single site catalyst and has aweight average molecular weight, M_(w), of at most 45,000; a molecularweight distribution, M_(w)/M_(n), of less than 3.0 and a density higherthan the density of said first ethylene copolymer, but less than 0.967g/cm³.

In an embodiment of the invention, a single site catalyst is used andthe ethylene copolymer has a CDBI(50) of at least about 65% by weight,or at least about 70%, or at least about 75%, or at least about 80%, orat least about 85%, during solution phase polymerization in a singlereactor, is used in the preparation of the second ethylene copolymer.

In an embodiment of the present invention, the second ethylene copolymerhas a CDBI(50) of greater than about 60% by weight, or greater thanabout 65%, or greater than about 70%, or greater than about 75%, orgreater than about 80%, or greater than about 85%.

The second ethylene copolymer can comprise from about 90 to about 30 wt% of the total weight of the first and second ethylene copolymers. In anembodiment of the invention, the second ethylene copolymer comprisesfrom about 80 to about 40 wt % of the total weight of the first andsecond ethylene copolymers. In an embodiment of the invention, thesecond ethylene copolymer comprises from about 75 to about 40 wt % ofthe total weight of the first and second ethylene copolymers. In anembodiment of the invention, the second ethylene copolymer comprisesfrom about 70 to about 40 wt % of the total weight of the first andsecond ethylene copolymers. In an embodiment of the invention, thesecond ethylene copolymer comprises from about 60 to about 50 wt % ofthe total weight of the first and second ethylene copolymers.

In embodiments of the invention, the melt index I₂ of the secondethylene copolymer is at least 50 times, or at least 100 times, or atleast 1,000 times the melt index I₂ of the first ethylene copolymer.

The Polyethylene Composition

In one embodiment the polyethylene composition will contain a firstethylene copolymer and a second ethylene copolymer (as defined herein).

In some embodiments of the invention, the polyethylene composition has aunimodal, broad unimodal, bimodal or multimodal molecular weightdistribution as determined by gel permeation chromatography.

In an embodiment of the invention, the polyethylene composition thatcomprises a first ethylene copolymer and a second ethylene copolymer (asdefined above) will have a ratio (SCB1/SCB2) of the number of shortchain branches per thousand carbon atoms in the first ethylene copolymer(i.e., SCB1) to the number of short chain branches per thousand carbonatoms in the second ethylene copolymer (i.e., SCB2) of greater than 1.0(i.e., SCB1/SCB2>1.0).

In further embodiments of the invention, the ratio of the short chainbranching in the first ethylene copolymer (SCB1) to the short chainbranching in the second ethylene copolymer (SCB2) is at least 1.25. Instill another embodiment of the invention, the ratio of the short chainbranching in the first ethylene copolymer (SCB1) to the short chainbranching in the second ethylene copolymer (SCB2) is at least 1.5.

In embodiments of the invention, the ratio (SCB1/SCB2) of the shortchain branching in the first ethylene copolymer (SCB1) to the shortchain branching in the second ethylene copolymer (SCB2) will be fromgreater than 1.0 to about 12.0, or from greater than 1.0 to about 10, orfrom greater than 1.0 to about 7.0, or from greater than 1.0 to about5.0, or from greater than 1.0 to about 3.0.

In an embodiment of the invention, the polyethylene composition isbimodal as determined by GPC.

A bimodal or multimodal polyethylene composition can be identified byusing gel permeation chromatography (GPC). A GPC chromatograph mayexhibit two or more component ethylene copolymers, where the number ofcomponent ethylene copolymers corresponds to the number of discerniblepeaks. One or more component ethylene copolymers may also exist as ahump, shoulder or tail relative to the molecular weight distribution ofthe other ethylene copolymer component. By the phrase “bimodal asdetermined by GPC”, it is meant that in addition to a first peak, therewill be a secondary peak or shoulder which represents a higher or lowermolecular weight component (i.e., the molecular weight distribution, canbe said to have two maxima in a molecular weight distribution curve).Alternatively, the phrase “bimodal as determined by GPC” connotes thepresence of two maxima in a molecular weight distribution curvegenerated according to the method of ASTM D6474-99.

The polyethylene composition of the current invention has a density ofgreater than or equal to 0.950 g/cm³, as measured according to ASTMD792; a melt index I₂, of from about 2 to about 22 g/10 min, as measuredaccording to ASTM D1238 (when conducted at 190° C., using a 2.16 kgweight); a molecular weight distribution, M_(w)/M_(n), of from about 2to about 7, a Z-average molecular weight M_(z), of less than about300,000; a stress exponent of less than 1.40; and an ESCR Condition B at100% Igepal of at least about 3 hours.

In embodiments of the invention, the polyethylene composition has acomonomer content of less than about 0.75 mol %, or less than about 0.70mol %, or less than about 0.65 mol %, or less than about 0.60 mol %, orless than about 0.55 mol %, or less than about 0.50 mol % as measured byFTIR or ¹³C NMR methods, where the comonomer is one or more suitablealpha olefins, which include, but are not limited to, 1-butene,1-hexene, 1-octene and the like. In one embodiment the alpha olefin is1-octene.

In the present invention, the polyethylene composition has a density ofat least 0.950 g/cm³. In further embodiments of the invention, thepolyethylene composition has a density of >0.952 g/cm³, or >0.953 g/cm³,or >0.955 g/cm³.

In an embodiment of the invention, the polyethylene composition has adensity in the range of 0.950 to 0.970 g/cm³. In an embodiment of thecurrent invention, the polyethylene composition has a density in therange of 0.950 to 0.965 g/cm³.

In an embodiment of the invention, the polyethylene composition has adensity in the range of 0.950 to 0.962 g/cm³.

In an embodiment of the invention, the polyethylene composition has adensity in the range of 0.952 to 0.960 g/cm³.

In an embodiment of the invention, the polyethylene composition has adensity in the range of 0.950 to 0.960 g/cm³.

In an embodiment of the invention, the polyethylene composition has adensity in the range of 0.950 to 0.959 g/cm³.

In an embodiment of the invention, the polyethylene composition has adensity in the range of 0.951 to 0.957 g/cm³.

In an embodiment of the invention, the polyethylene composition has adensity in the range of 0.952 to 0.957 g/cm³.

In an embodiment of the invention, the polyethylene composition has amelt index I₂, of from 2 to 22 g/10 min according to ASTM D1238 (whenconducted at 190° C., using a 2.16 kg weight) and including narrowerranges within this range and all numbers encompassed by these ranges.For example, in further embodiments of the invention, the polyethylenecomposition has a melt index I₂, of greater than 2, but less than 22g/10 min, or from 2 to 15.0 g/10 min, or from 3 to 12.5 g/10 min, orfrom 4 to 12.5 g/10 min, or from greater than 4 to less than 20 g/10min, or from 4.5 to 10 g/10 min, or from 5 to 20 g/10 min, or fromgreater than 5.0 to less than 20 g/10 min, or from 3 to 15.0 g/10 min,or from 6.0 to 12.0 g/10 min, or from 6.0 to about 10.0 g/10 min, orfrom about 5.0 to about 12.0 g/10 min, or from more than about 5.0 toless than about 10.0 g10/min.

In an embodiment of the invention, the polyethylene composition has a“medium load” melt index, I₅, of at least about 2.5 g/10 min accordingto ASTM D1238 (when conducted at 190° C., using a 5 kg weight). Inanother embodiment of the invention, the polyethylene composition has amedium load melt index, I₅, of greater than about 5.0 g/10 min, asmeasured according to ASTM D1238 (when conducted at 190° C., using a 5kg weight). In further embodiments of the invention, the polyethylenecomposition has a medium load melt index, I₅, of at least about 10.0g/10 min, or at least about 4.0 g/10 min. In still further embodimentsof the invention, the polyethylene composition has a medium load meltindex, I₅, of from about 5.0 to about 25.0 g/10 min, or from about 5.0to about 20.0 g/10 min, or from about 5.0 to about 17.5 g/10 min, orfrom about 5.0 to about 15.0 g/10 min.

In an embodiment of the invention, the polyethylene composition has a“high load” melt index I₂₁ of at least about 100 g/10 min according toASTM D1238 (when conducted at 190° C., using a 21 kg weight). In anotherembodiment of the invention, the polyethylene composition has a highload melt index I₂₁, of greater than about 150 g/10 min.

In an embodiment of the invention, the polyethylene composition has ahigh load melt index I₂₁, of from 125 to 500 g/10 min, or from 150 to450 g/10 min, or from 150 to 400 g/10 min.

In an embodiment of the invention, the polyethylene composition has anumber average molecular weight M_(n), of below about 30,000 g/mol. Inanother embodiment of the invention, the polyethylene composition has anumber average molecular weight M_(n), of below about 25,000 g/mol. Inyet another embodiment of the invention, the polyethylene compositionhas a number average molecular weight M_(n), of below about 20,000g/mol.

In the present invention, the polyethylene composition has a molecularweight distribution M_(w)/M_(n), of from 2 to 7 or a narrower rangewithin this range, including all the numbers encompassed within theseranges. For example, in further embodiments of the invention, thepolyethylene composition has molecular weight distribution M_(w)/M_(n),of from 3.0 to 7.0, or from 3.5 to 6.0, or from 3.5 to 5.5.

In an embodiment of the invention, the polyethylene composition has aZ-average molecular weight, M_(z), of below about 300,000 g/mole. Inanother embodiment of the invention, the polyethylene composition has aZ-average molecular weight, M_(z), of below about 250,000 g/mole. In yetanother embodiment of the invention, the polyethylene composition has aZ-average molecular weight, M_(z), of below about 200,000 g/mole.

In embodiments of the invention, the polyethylene composition has aratio of Z-average molecular weight to weight average molecular weightM_(Z)/M_(W), of from 2.0 to 4.0, or from 2.0 to 3.75, or from 2.25 to3.75, or from 2.50 to 3.5.

In embodiments of the invention, the polyethylene composition has a meltflow ratio defined as I₂₁/I₂, of from about 15 to about 50, or fromabout 20 to 50, or from about 22 to 50, or from about 25 to 45, or fromabout 30 to 45, or from about 30 to 50, or from 22 to 50, or from about22 to less than 50.

In an embodiment of the invention, the polyethylene composition has amelt flow rate defined as I₂₁/I₅, of less than 25. In another embodimentof the invention, the polyethylene composition has a melt flow ratedefined as I₂₁/I₅, of less than 20. In another embodiment of theinvention, the polyethylene composition has a melt flow rate defined asI₂₁/I₅, of less than 15.

In an embodiment of the invention, the polyethylene composition has ashear viscosity at about 10⁵ s⁻¹ (240° C.) of less than about 10 (Pa·s).In further embodiments of the invention, the polyethylene compositionhas a shear viscosity at about 10⁵ s⁻¹ (240° C.) of less than 7.5 Pa·s,or less than 6.8 Pa·s. Simultaneously, the polyethylene composition mayhave a shear viscosity at about 100 s⁻¹ (240° C.) of less than about 600Pa·s, a shear viscosity at about 200 s⁻¹ (240° C.) of less than about500 Pa·s and a shear viscosity at about 300 s⁻¹ (240° C.) of less thanabout 400 Pa·s.

In an embodiment of the invention, the polyethylene composition has atleast one type of alpha-olefin that has at least 4 carbon atoms and itscontent is less than about 0.75 mol % as determined by ¹³C NMR. In anembodiment of the invention, the polyethylene composition has at leastone type of alpha-olefin that has at least 4 carbon atoms and itscontent is less than about 0.65 mol % as determined by ¹³C NMR. In anembodiment of the invention, the polyethylene composition has at leastone type of alpha-olefin that has at least 4 carbon atoms and itscontent is less than about 0.55 mol % as determined by ¹³C NMR. In anembodiment of the invention, the polyethylene composition has at leastone type of alpha-olefin that has at least 4 carbon atoms and itscontent is less than about 0.50 mol % as determined by ¹³C NMR. In anembodiment of the invention, the polyethylene composition has at leastone type of alpha-olefin that has at least 4 carbon atoms and itscontent is greater than about 0.20 to less than about 0.55 mol % asdetermined by ¹³C NMR.

In an embodiment of the invention, the shear viscosity ratio,SVR(_(100,100000)) at 240° C. of the polyethylene composition can befrom about 50 to about 90, or can be from about 55 to about 90, or fromabout 55 to about 85, or from about 55 to about 75. The shear viscosityratio SVR(_(100,100000)) is determined by taking the ratio of shearviscosity at shear rate of 100 s⁻¹ and shear viscosity at shear rate of100000 s⁻¹ as measured with a capillary rheometer at constanttemperature (e.g. 240° C.), and two dies with L/D ratio of 20 anddiameter of 0.06″ (from about 3 to 1000 s⁻¹) and L/D ratio of 20 anddiameter of 0.012″ (from about 1000 to 100000 s¹) respectively.

In an embodiment of the invention, the polyethylene composition or amolded article made from the polyethylene composition, has anenvironment stress crack resistance ESCR Condition B at 100% of at leastabout 3 hrs., as measured according to ASTM D1693 (at 50° C. using 100%Igepal, condition B).

In an embodiment of the invention, the polyethylene composition or amolded article made from the polyethylene composition, has anenvironment stress crack resistance ESCR Condition B at 100% of at leastabout 3.5 hrs, as measured according to ASTM D1693 (at 50° C. using 100%Igepal, condition B).

In an embodiment of the invention, the polyethylene composition or amolded article made from the polyethylene composition, has anenvironment stress crack resistance ESCR Condition B at 100% of at leastabout 4.0 hrs., as measured according to ASTM D1693 (at 50° C. using100% Igepal, condition B).

In an embodiment of the invention, the polyethylene composition or amolded article made from the polyethylene composition, has anenvironment stress crack resistance ESCR Condition B at 100% of fromabout 3.5 to about 15 hrs., as measured according to ASTM D1693 (at 50°C. using 100% Igepal, condition B).

In an embodiment of the invention, the polyethylene composition or amolded article made from the polyethylene composition, has anenvironment stress crack resistance ESCR Condition B at 100% of fromabout 3.5 to about 12 hrs., as measured according to ASTM D1693 (at 50°C. using 100% Igepal, condition B).

In an embodiment of the invention, the polyethylene composition or amolded article made from the polyethylene composition has a notched Izodimpact strength of at least about 40 J/m, as measured according to ASTMD256.

In embodiments of the invention, the polyethylene composition has aTD/MD shrinkage ratio (for an injection molded disk at about 48 hrs postmolding) of from about 0.90 to about 1.20, or from about 0.90 to about1.15, or from about 0.95 to about 1.15, or from about 0.90 to about1.10, or from about 0.95 to about 1.10, or from about 0.95 to about 1.05when measured according to the Dimensional Stability Test (DST).

In embodiments of the invention, the polyethylene composition has a TDshrinkage-MD shrinkage (for an injection molded disk at about 48 hourpost molding time) of from about 0.25 to about 0.25, or from about 0.20to about 0.20, or from about 0.15 to about 0.15, or from about 0.10 toabout 0.10, or from about 0.075 to about 0.075, or from about 0.05 toabout 0.05, when measured according to the Dimensional Stability Test(DST).

In an embodiment of the invention the polyethylene composition of thecurrent invention has a density of from 0.950 to 0.960 g/cm³; a meltindex I₂, of from 3 to 12 g/10 min; a molecular weight distributionM_(w)/M_(n), of from 2.0 to 7.0; a number average molecular weightM_(n), of below 30,000; a shear viscosity at 10⁵ s⁻¹ (240° C.) of lessthan 10 (Pa·s), a hexane extractables of less than 0.55%, a notched Izodimpact strength of more than 40 J/m, and an ESCR B at 100% of at leastabout 3.5 hrs.

In an embodiment of the invention, the polyethylene composition has ahexanes extractables of less than about 0.55%. In further embodiments ofthe invention, the polyethylene composition has a hexanes extractablesof less than about 0.50%, or less than about 0.45%, or less than about0.40%, or less than about 0.35%.

In an embodiment of the invention, the polyethylene composition has astress exponent, defined as Log₁₀[I₆/I₂]/Log₁₀[6.48/2.16], which is≦1.40. In further embodiments of the invention, the polyethylenecomposition has a stress exponent, Log₁₀[I₆/I₂]/Log₁₀[6.48/2.16] of from1.22 to 1.40, or from 1.22 to 1.38, or from 1.24 to 1.36.

In an embodiment of the invention, the polyethylene composition has acomposition distribution breadth index (CDBI(50)), as determined bytemperature elution fractionation (TREF), of ≧about 60 weight percent.In further embodiments of the invention, the polyethylene compositionwill have a CDBI(50) of greater than about 65%, or greater than about70%, or greater than about 75%, or greater than about 80%.

In an embodiment of the invention, the polyethylene composition has acomposition distribution breadth index (CDBI(25)), as determined bytemperature elution fractionation (TREF), of ≧about 55 weight percent.In further embodiments of the invention, the polyethylene compositionwill have a CDBI(25) of greater than about 60%, or greater than about65%, or from about 55 to about 75%, or from about 60 to about 75%.

The polyethylene composition of this invention can be made using anyconventional blending method such as but not limited to physicalblending and in-situ blending by polymerization in multi reactorsystems. For example, it is possible to perform the mixing of the firstethylene copolymer with the second ethylene copolymer by molten mixingof the two preformed polymers. One embodiment uses processes in whichthe first and second ethylene copolymers are prepared in at least twosequential polymerization stages, however, both in-series or anin-parallel dual reactor process are contemplated for use in the currentinvention. Gas phase, slurry phase or solution phase reactor systems maybe used. In one embodiment a solution phase reactor systems is used.

Mixed catalyst single reactor systems may also be employed to make thepolymer compositions of the present invention.

In an embodiment of the current invention, a dual reactor solutionpolymerization process is used as has been described in for example U.S.Pat. No. 6,372,864 and U.S. Pat. Appl. No. 20060247373A1 which areincorporated herein by reference.

Generally, the catalysts used in the current invention will be so calledsingle site catalysts based on a group 4 metal having at least onecyclopentadienyl ligand. Examples of such catalysts includemetallocenes, constrained geometry catalysts and phosphinimine catalystsused, for example, in combination with activators selected frommethylaluminoxanes, boranes or ionic borate salts and are furtherdescribed in U.S. Pat. Nos. 3,645,992; 5,324,800; 5,064,802; 5,055,438;6,689,847; 6,114,481 and 6,063,879. Such single site catalysts aredistinguished from traditional Ziegler-Natta or Phillips catalysts whichare also well known in the art. In general, single site catalystsproduce ethylene copolymers having a molecular weight distribution(M_(w)/M_(n)) of less than about 3.0 and a composition distributionbreadth index CDBI(50) of greater than about 65%.

In an embodiment of the invention, a single site catalyst is used tomake an ethylene copolymer having a CDBI(50) of at least about 65% byweight, or at least about 70%, or at least about 75%, or at least about80%, or at least about 85%, during solution phase polymerization in asingle reactor, for the preparation of each of the first and the secondethylene copolymers.

In an embodiment of the invention, homogeneously branched ethylenecopolymers are prepared using an organometallic complex of a group 3, 4or 5 metal that is further characterized as having a phosphinimineligand. Such a complex, when active toward olefin polymerization, isknown generally as a phosphinimine (polymerization) catalyst. Somenon-limiting examples of phosphinimine catalysts can be found in U.S.Pat. Nos. 6,342,463; 6,235,672; 6,372,864; 6,984,695; 6,063,879;6,777,509 and 6,277,931 all of which are incorporated by referenceherein.

Some non-limiting examples of metallocene catalysts can be found in U.S.Pat. Nos. 4,808,561; 4,701,432; 4,937,301; 5,324,800; 5,633,394;4,935,397; 6,002,033 and 6,489,413, which are incorporated herein byreference. Some non-limiting examples of constrained geometry catalystscan be found in U.S. Pat. Nos. 5,057,475; 5,096,867; 5,064,802;5,132,380; 5,703,187 and 6,034,021, all of which are incorporated byreference herein in their entirety.

In an embodiment of the invention, use of a single site catalyst thatdoes not produce long chain branching (LCB) is used. Hexyl (C6) branchesdetected by NMR are excluded from the definition of a long chain branchin the present invention.

Without wishing to be bound by any single theory, long chain branchingcan increase viscosity at low shear rates, thereby negatively impactingcycle times during the manufacture of caps and closures, such as duringthe process of compression molding. Long chain branching may bedetermined using ¹³C NMR methods and may be quantitatively assessedusing the method disclosed by Randall in Rev. Macromol. Chem. Phys. C29(2 and 3), p. 285.

In an embodiment of the invention, the polyethylene composition willcontain fewer than 0.3 long chain branches per 1000 carbon atoms. Inanother embodiment of the invention, the polyethylene composition willcontain fewer than 0.01 long chain branches per 1000 carbon atoms.

In an embodiment of the invention, the polyethylene composition isprepared by contacting ethylene and at least one alpha-olefin with apolymerization catalyst under solution phase polymerization conditionsin at least two polymerization reactors (for an example of solutionphase polymerization conditions see for example U.S. Pat. Nos. 6,372,864and 6,984,695 and U.S. Patent Application 20060247373A1 which areincorporated herein by reference).

In an embodiment of the invention, the polyethylene composition isprepared by contacting at least one single site polymerization catalystsystem (comprising at least one single site catalyst and at least oneactivator) with ethylene and a least one comonomer (e.g., a C3-C8alpha-olefin) under solution polymerization conditions in at least twopolymerization reactors.

In an embodiment of the invention, a group 4 single site catalystsystem, comprising a single site catalyst and an activator, is used in asolution phase dual reactor system to prepare a polyethylene compositionby polymerization of ethylene in the presence of an alpha-olefincomonomer.

In an embodiment of the invention, a group 4 single site catalystsystem, comprising a single site catalyst and an activator, is used in asolution phase dual reactor system to prepare a polyethylene compositionby polymerization of ethylene in the presence of 1-octene.

In an embodiment of the invention, a group 4 phosphinimine catalystsystem, comprising a phosphinimine catalyst and an activator, is used ina solution phase dual reactor system to prepare a polyethylenecomposition by polymerization of ethylene in the presence of analpha-olefin comonomer.

In an embodiment of the invention, a group 4 phosphinimine catalystsystem, comprising a phosphinimine catalyst and an activator, is used ina solution phase dual reactor system to prepare a polyethylenecomposition by polymerization of ethylene in the presence of 1-octene.

In an embodiment of the invention, a solution phase dual reactor systemcomprises two solution phase reactors connected in series.

In an embodiment of the invention, a polymerization process to preparethe polyethylene composition comprises contacting at least one singlesite polymerization catalyst system (comprising at least one single sitecatalyst and at least one activator) with ethylene and at least onealpha-olefin comonomer under solution polymerization conditions in atleast two polymerization reactors.

In an embodiment of the invention, a polymerization process to preparethe polyethylene composition comprises contacting at least one singlesite polymerization catalyst system with ethylene and at least onealpha-olefin comonomer under solution polymerization conditions in afirst reactor and a second reactor configured in series.

In an embodiment of the invention, a polymerization process to preparethe polyethylene composition comprises contacting at least one singlesite polymerization catalyst system with ethylene and at least onealpha-olefin comonomer under solution polymerization conditions in afirst reactor and a second reactor configured in series, with the atleast one alpha-olefin comonomer being fed exclusively to the firstreactor.

In one embodiment, the production of the polyethylene composition of thepresent invention may include an extrusion or compounding step. Suchsteps are well known in the art.

In one embodiment, the polyethylene composition can comprise furtherpolymer components in addition to the first and second ethylenepolymers. Such polymer components include polymers made in situ orpolymers added to the polymer composition during an extrusion orcompounding step.

Optionally, additives can be added to the polyethylene composition.Additives can be added to the polyethylene composition during anextrusion or compounding step, but other suitable known methods will beapparent to a person skilled in the art. The additives can be added asis or as part of a separate polymer component (i.e. not the first orsecond ethylene polymers described above) added during an extrusion orcompounding step. Suitable additives are known in the art and includebut are not-limited to antioxidants, phosphites and phosphonites,nitrones, antacids, UV light stabilizers, UV absorbers, metaldeactivators, dyes, fillers and reinforcing agents, nano-scale organicor inorganic materials, antistatic agents, lubricating agents such ascalcium stearates, slip additives such as erucimide, and nucleatingagents (including nucleators, pigments or any other chemicals which mayprovide a nucleating effect to the polyethylene composition). Theadditives that can be optionally added may be added in amount of up toabout 20 weight percent (wt %).

One or more nucleating agent(s) may be introduced into the polyethylenecomposition by kneading a mixture of the polymer, usually in powder orpellet form, with the nucleating agent, which may be utilized alone orin the form of a concentrate containing further additives such asstabilizers, pigments, antistatics, UV stabilizers and fillers. Itshould be a material which is wetted or absorbed by the polymer, whichis insoluble in the polymer and of melting point higher than that of thepolymer, and it should be homogeneously dispersible in the polymer meltin as fine a form as possible (about 1 to about 10 μm). Compounds knownto have a nucleating capacity for polyolefins include salts of aliphaticmonobasic or dibasic acids or arylalkyl acids, such as sodium succinateor aluminum phenylacetate; and alkali metal or aluminum salts ofaromatic or alicyclic carboxylic acids such as sodium β-naphthoate.Another compound known to have nucleating capacity is sodium benzoate.The effectiveness of nucleation may be monitored microscopically byobservation of the degree of reduction in size of the spherulites intowhich the crystallites are aggregated.

In an embodiment of the invention, the polyethylene compositionsdescribed above are used in the formation of molded articles. Forexample, articles formed by compression molding and injection moldingare contemplated. Such articles include, for example, caps, screw caps,and closures for bottles, containers and the like. However, a personskilled in the art will readily appreciate that the compositionsdescribed above may also be used for other applications such as but notlimited to film, injection blow molding, blow molding and sheetextrusion applications.

In an embodiment of the invention, the polyethylene compositionsdescribed above are used in the formation of a closure for bottles,containers and the like. For example, closures for bottles formed bycompression molding or injection molding are contemplated. Such closuresinclude, for example, hinged caps, hinged screw caps, hinged snap-topcaps, and hinged closures for bottles, containers and the like.

In an embodiment of the invention, a closure (or cap) is a screw cap fora bottle, container and the like.

In an embodiment of the invention, a closure (or cap) comprises a hingemade of the same material as the rest of the closure (or cap).

In an embodiment of the invention, a closure (or cap) is hinged closure.

In an embodiment of the invention, a closure (or cap) is a hingedclosure for bottles, containers and the like.

In an embodiment of the invention, a closure (or cap) is a flip-tophinge closure, such as a flip-top hinge closure for use on a plasticketchup bottle or similar containers containing foodstuffs.

When a closure is a hinged closure, it comprises a hinged component andgenerally consists of at least two bodies which are connected by athinner section that acts as a hinge allowing the at least two bodies tobend from an initially molded position. The thinner section may becontinuous or web-like, wide or narrow.

A useful closure (for bottles, containers and the like) is a hingedclosure and may consist of two bodies joined to each other by at leastone thinner bendable portion (e.g. the two bodies can be joined by asingle bridging portion, or more than one bridging portion, or by awebbed portion, etc.). A first body may contain a dispensing hole andwhich may snap onto or screw onto a container to cover a containeropening (e.g. a bottle opening) while a second body may serve as a snapon lid which may mate with the first body.

The caps and closures, of which hinged caps and closures are a subset,can be made according to any known method, including for exampleinjection molding and compression molding techniques that are well knownto persons skilled in the art. Hence, in an embodiment of the inventiona closure (or cap) comprising the polyethylene composition (definedabove) is prepared with a process comprising at least one compressionmolding step and/or at least one injection molding step.

In one embodiment, the caps and closures (including single piece ormulti-piece variants including hinged variants) comprise thepolyethylene composition described above and have very good dimensionalstability, good organoleptic properties, good toughness, as well asreasonable ESCR values. Hence the closures and caps of this embodimentare well suited for sealing bottles, containers and the like, forexamples bottles that may contain drinkable water, and other foodstuffs,including but not limited to liquids that are non-pressurized. Theclosures and caps may also be used for sealing bottles containingdrinkable water or non-carbonated beverages (e.g. juice). Otherapplications, include caps and closures for bottles and containerscontaining foodstuffs, such as for example ketchup bottles and the like.

In an embodiment of the invention, homogeneously branched ethylenecopolymers are prepared using an organometallic complex of a group 3, 4or 5 metal that is further characterized as having a phosphinimineligand. Such a complex, when active toward olefin polymerization, isknown generally as a phosphinimine (polymerization) catalyst.

An embodiment of the invention is a closure, for example a closure for abottle, a container and the like, the closure being a hinged closurecomprising a polyethylene composition, the polyethylene compositioncomprising:

(1) about 10 to about 70 wt % of a first ethylene copolymer having amelt index I₂, of from 0.1 to 10 g/10 min; a molecular weightdistribution M_(w)/M_(n), of less than 3.0; and a density of from 0.930to 0.960 g/cm³; and

(2) about 90 to about 30 wt % of a second ethylene copolymer having amelt index I₂, of from 50 to 10,000 g/10 min; a molecular weightdistribution M_(w)/M_(n), of less than 3.0; and a density higher thanthe density of the first ethylene copolymer, but less than 0.966 g/cm³;

wherein the density of the second ethylene copolymer is less than

0.037 g/cm³ higher than the density of the first ethylene copolymer; theratio (SCB1/SCB2) of the number of short chain branches per thousandcarbon atoms in the first ethylene copolymer (SCB1) to the number ofshort chain branches per thousand carbon atoms in the second ethylenecopolymer (SCB2) is greater than 1.0; and wherein the polyethylenecomposition has a molecular weight distribution M_(w)/M_(n), of from 2to 7; a density of at least 0.950 g/cm³; a high load melt index I₂₁, offrom 150 to 400 g/10 min; a Z-average molecular weight M_(Z), of lessthan about 300,000; a melt flow ratio I₂₁/I₂, of from 22 to 50; a stressexponent of less than 1.40; and an ESCR Condition B (100% IGEPAL) of atleast about 3.5 hrs.

In an embodiment of the invention, the polyethylene composition has aTD/MD shrinkage ratio of from about 0.90 to about 1.15 when measuredaccording to the Dimensional Stability Test (DST).

In an embodiment of the invention, the polyethylene composition has anESCR Condition B (100% IGEPAL) of from about 3.5 to about 15 hrs.

In an embodiment of the invention, the polyethylene composition has amelt index I₂, of greater than 5.0 to less than 20 g/10 min.

In an embodiment of the invention, the first and second ethylenecopolymers are made by polymerizing ethylene and an alpha olefin in thepresence of a single site catalyst.

In an embodiment of the invention, the density of the second ethylenecopolymer is less than 0.030 g/cm³ higher than the density of the firstethylene copolymer.

In an embodiment of the invention, the first ethylene copolymer has amelt index I₂, of from 0.1 to 3.0 g/10 min.

In an embodiment of the invention, the second ethylene copolymer has amelt index I₂, of from 100 to 5000 g/10 min.

In an embodiment of the invention, the polyethylene composition has amelt index I₂, of from 6 to 12 g/10 min.

In an embodiment of the invention, the polyethylene composition has abimodal molecular weight distribution as determined by gel permeationchromatography.

In an embodiment of the invention, the ratio (SCB1/SCB2) of the numberof short chain branches per thousand carbon atoms in the first ethylenecopolymer (SCB1) to the number of short chain branches per thousandcarbon atoms in the second ethylene copolymer (SCB2) is at least 1.5.

In an embodiment of the invention, the polyethylene composition has amolecular weight distribution M_(w)/M_(n), of from 3.5 to 6.

In an embodiment of the invention, the first ethylene copolymer has adensity of from 0.936 to 0.952 g/cm³.

In an embodiment of the invention, the second ethylene copolymer has adensity of less than 0.965 g/cm³.

In an embodiment of the invention, the polyethylene composition has adensity of from 0.952 to 0.960 g/cm³.

In an embodiment of the invention, the polyethylene composition has nolong chain branching.

In an embodiment of the invention, the first and second ethylenecopolymers have a M_(w)/M_(n) of less than 2.5.

In an embodiment of the invention, the polyethylene composition has acomposition distribution breadth index (CDBI(50)) of greater than about65 wt %.

In an embodiment of the invention, the first and second ethylenecopolymers each have a composition distribution breadth index (CDBI(50))of greater than about 65 wt %.

In an embodiment of the invention, the polyethylene compositioncomprises: from about 25 to about 60 wt % of the first ethylenecopolymer; and from about 75 to about 40 wt % of the second ethylenecopolymer.

In an embodiment of the invention, the polyethylene composition has acomonomer content of less than about 0.5 mol % as determined by ¹³C NMR.

In an embodiment of the invention, the polyethylene composition furthercomprises a nucleating agent or a combination of nucleating agents.

In an embodiment of the invention, the first and second ethylenecopolymers are copolymers of ethylene and 1-octene.

In an embodiment of the invention, the closure is made by compressionmolding or injection molding.

In an embodiment of the invention, the closure is a screw cap.

In an embodiment of the invention, the polyethylene composition isprepared by contacting ethylene and an alpha-olefin with a single sitepolymerization catalyst under solution polymerization conditions in aleast two polymerization reactors.

An embodiment of the invention is a closure, for example a closure for abottle, a container and the like, the closure being a hinged closurecomprising a polyethylene composition.

An embodiment of the invention is a process for preparing a closure, forexample a closure for a bottle, a container and the like, the closurebeing a hinged closure, wherein the process comprises at least onecompression molding or injection molding step and wherein the closurecomprises a polyethylene composition, the polyethylene compositioncomprising:

(1) about 10 to about 70 wt % of a first ethylene copolymer having amelt index I₂, of from 0.1 to 10 g/10 min; a molecular weightdistribution M_(w)/M_(n), of less than 3.0; and a density of from 0.930to 0.960 g/cm³; and

(2) about 90 to about 30 wt % of a second ethylene copolymer having amelt index I₂, of from 50 to 10,000 g/10 min; a molecular weightdistribution M_(w)/M_(n), of less than 3.0; and a density higher thanthe density of the first ethylene copolymer, but less than 0.966 g/cm³;

wherein the density of the second ethylene copolymer is less than

0.037 g/cm³ higher than the density of the first ethylene copolymer; theratio (SCB1/SCB2) of the number of short chain branches per thousandcarbon atoms in the first ethylene copolymer (SCB1) to the number ofshort chain branches per thousand carbon atoms in the second ethylenecopolymer (SCB2) is greater than 1.0; and wherein the polyethylenecomposition has a molecular weight distribution M_(w)/M_(n), of from 2to 7; a density of at least 0.950 g/cm³; a high load melt index I₂₁, offrom 150 to 400 g/10 min; a Z-average molecular weight M_(Z), of lessthan about 300,000; a melt flow ratio I₂₁/I₂, of from 22 to 50; a stressexponent of less than 1.40; and an ESCR Condition B (100% IGEPAL) of atleast about 3.5 hrs.

The invention is further illustrated by the following non-limitingexamples. Unless otherwise indicated, all percentages are by weightunless otherwise specified.

EXAMPLES

Melt indexes, I₂, I₅, I₆ and I₂₁ for the polyethylene composition weremeasured according to ASTM D1238 (when conducted at 190° C., using a2.16 kg, a 5 kg, a 6.48 kg and a 21 kg weight respectively).

M_(n), M_(w), and M_(z) (g/mol) were determined by high temperature GelPermeation Chromatography with differential refractive index detectionusing universal calibration (e.g. ASTM-D6474-99). GPC data was obtainedusing an instrument sold under the trade name “Waters 150c”, with1,2,4-trichlorobenzene as the mobile phase at 140° C. The samples wereprepared by dissolving the polymer in this solvent and were run withoutfiltration. Molecular weights are expressed as polyethylene equivalentswith a relative standard deviation of 2.9% for the number averagemolecular weight (“Mn”) and 5.0% for the weight average molecular weight(“Mw”). The molecular weight distribution (MWD) is the weight averagemolecular weight divided by the number average molecular weight,M_(w)/M_(n). The z-average molecular weight distribution is M_(z)/M_(n).Polymer sample solutions (1 to 2 mg/mL) were prepared by heating thepolymer in 1,2,4-trichlorobenzene (TCB) and rotating on a wheel for 4hours at 150° C. in an oven. The antioxidant2,6-di-tert-butyl-4-methylphenol (BHT) was added to the mixture in orderto stabilize the polymer against oxidative degradation. The BHTconcentration was 250 ppm. Sample solutions were chromatographed at 140°C. on a PL 220 high-temperature chromatography unit equipped with fourShodex columns (HT803, HT804, HT805 and HT806) using TCB as the mobilephase with a flow rate of 1.0 mL/minute, with a differential refractiveindex (DRI) as the concentration detector. BHT was added to the mobilephase at a concentration of 250 ppm to protect the columns fromoxidative degradation. The sample injection volume was 200 mL. The rawdata were processed with Cirrus GPC software. The columns werecalibrated with narrow distribution polystyrene standards. Thepolystyrene molecular weights were converted to polyethylene molecularweights using the Mark-Houwink equation, as described in the ASTMstandard test method D6474.

Primary melting peak (° C.), heat of fusion (J/g) and crystallinity (%)was determined using differential scanning calorimetry (DSC) as follows:the instrument was first calibrated with indium; after the calibration,a polymer specimen is equilibrated at 0° C. and then the temperature wasincreased to 200° C. at a heating rate of 10° C./min; the melt was thenkept isothermally at 200° C. for five minutes; the melt was then cooledto 0° C. at a cooling rate of 10° C./min and kept at 0° C. for fiveminutes; the specimen was then heated to 200° C. at a heating rate of10° C./min. The DSC Tm, heat of fusion and crystallinity are reportedfrom the 2^(nd) heating cycle.

The short chain branch frequency (SCB per 1000 carbon atoms) of thepolyethylene composition was determined by Fourier Transform InfraredSpectroscopy (FTIR) as per the ASTM D6645-01 method. A Thermo-Nicolet750 Magna-IR Spectrophotometer equipped with OMNIC version 7.2a softwarewas used for the measurements. Unsaturations in the polyethylenecomposition were also determined by Fourier Transform InfraredSpectroscopy (FTIR) as per ASTM D3124-98. Comonomer content can also bemeasured using ¹³C NMR techniques as discussed in Randall, Rev.Macromol. Chem. Phys., C29 (2&3), p 285; U.S. Pat. No. 5,292,845 and WO2005/121239.

Polyethylene composition density (g/cm³) was measured according to ASTMD792.

Hexane extractables were determined according to ASTM D5227.

Shear viscosity was measured by using a Kayeness WinKARS CapillaryRheometer (model #D5052M-115). For the shear viscosity at lower shearrates, a die having a die diameter of 0.06 inch and L/D ratio of 20 andan entrance angle of 180 degrees was used. For the shear viscosity athigher shear rates, a die having a die diameter of 0.012 inch and L/Dratio of 20 was used.

The Processability Indicator:

The “processability indicator” as used herein is defined as:Processability Indicator=100/η(10⁵ s⁻¹,240° C.);where η is the shear viscosity measured at 10⁵ 1/s at 240° C.

To determine CDBI(50), a solubility distribution curve is firstgenerated for the polyethylene composition. This is accomplished usingdata acquired from the TREF technique. This solubility distributioncurve is a plot of the weight fraction of the copolymer that issolubilized as a function of temperature. This is converted to acumulative distribution curve of weight fraction versus comonomercontent, from which the CDBI(50) is determined by establishing theweight percentage of a copolymer sample that has a comonomer contentwithin 50% of the median comonomer content on each side of the median(See WO 93/03093 and U.S. Pat. No. 5,376,439). The CDBI(25) isdetermined by establishing the weight percentage of a copolymer samplethat has a comonomer content within 25% of the median comonomer contenton each side of the median

The temperature rising elution fractionation (TREF) method used hereinwas as follows. Polymer samples (50 to 150 mg) were introduced into thereactor vessel of a crystallization-TREF unit (Polymer ChAR™). Thereactor vessel was filled with 20 to 40 ml 1,2,4-trichlorobenzene (TCB),and heated to the desired dissolution temperature (e.g., 150° C.) for 1to 3 hours. The solution (0.5 to 1.5 ml) was then loaded into the TREFcolumn filled with stainless steel beads. After equilibration at a givenstabilization temperature (e.g., 110° C.) for 30 to 45 minutes, thepolymer solution was allowed to crystallize with a temperature drop fromthe stabilization temperature to 30° C. (0.1 or 0.2° C./minute). Afterequilibrating at 30° C. for 30 minutes, the crystallized sample waseluted with TCB (0.5 or 0.75 mL/minute) with a temperature ramp from 30°C. to the stabilization temperature (0.25 or 1.0° C./minute). The TREFcolumn was cleaned at the end of the run for 30 minutes at thedissolution temperature. The data were processed using Polymer ChARsoftware, Excel spreadsheet and TREF software developed in-house.

High temperature GPC equipped with an online FTIR detector (GPC-FTIR)was used to measure the comonomer content as the function of molecularweight.

Plaques molded from the polyethylene compositions were tested accordingto the following ASTM methods: Bent Strip Environmental Stress CrackResistance (ESCR) at Condition B at 100% IGEPAL at 50° C., ASTM D1693;notched Izod impact properties, ASTM D256; Flexural Properties, ASTM D790; Tensile properties, ASTM D 638; Vicat softening point, ASTM D 1525;Heat deflection temperature, ASTM D 648.

Dynamic mechanical analyses were carried out with a rheometer, namelyRheometrics Dynamic Spectrometer (RDS-II) or Rheometrics SR5 or ATSStresstech, on compression molded samples under nitrogen atmosphere at190° C., using 25 mm diameter cone and plate geometry. The oscillatoryshear experiments were done within the linear viscoelastic range ofstrain (10% strain) at frequencies from 0.05 to 100 rad/s. The values ofstorage modulus (G′), loss modulus (G″), complex modulus (G*) andcomplex viscosity (η*) were obtained as a function of frequency. Thesame rheological data can also be obtained by using a 25 mm diameterparallel plate geometry at 190° C. under nitrogen atmosphere.

Dimensional Stability Test (DST):

The dimensional stability of the polyethylene compositions wasdetermined as follows: A 150-ton×12-Oz Cincinnati Milacron injectionmolding machine (Hydradamp 150 T 12 oz PC-111, serial #4001 A21/79-38)with a 2 inch (50.8 mm) screw was used to produce parts according to theconditions listed in Table 1. The mold was an ASTM test mold, whichmakes tensile test specimens with an overall length of 1.30 inches, anoverall width of 0.75 inch, and a thickness of 0.12 inch; tensile testspecimens with an overall length of 1.375 inch, an overall width of0.375 inch, and a thickness of 0.12 inch; tensile test specimens with anoverall length of 2.5 inch, an overall width of 0.375 inch, and athickness of 0.12 inch; flexural modulus bars with a length of 5 inch, awidth of 0.50 inch, and a thickness of either 0.12 inch or 0.75 inch,and an impact round disk with a diameter of 2 inch and a thickness of0.12 inch. Immediately after molding, the injection-molded disk wasremoved from the runner (note: an injection molded disk with a 2 inchdiameter and a thickness of 0.12 inches was used for measurements in thepresent invention). The diameters in both the machine (or in-flow)direction (MD) and transverse-flow direction (TD) are then measured atroom temperature (23±2° C.) after 1, 24 and 48 hrs. of molding.Shrinkage at time t is defined as the percentage change in dimension atmeasurement time from the original mold dimensions:Shrinkage percent=(Mold dimension−Specimen dimension at time t)×100/Molddimension

Thus, MD shrinkage is the shrinkage measured on the disk in the flowdirection, and Transverse direction (TD) shrinkage is the shrinkagemeasured in the cross-flow direction. Here, the isotropic shrinkage isdefined as the equal shrinkage in both the flow direction (in-flow) andthe transverse direction. Differential shrinkage is defined as TDshrinkage minus MD shrinkage (an indication of part planarity orflatness or the extent of part warpage). The smaller the difference itis, the better the part planarity. A TD/MD shrinkage ratio, the TDshrinkage divided by MD shrinkage, can also be used as a measure of theextent of isotropic shrinkage (the closer to unity it is, the better thepart planarity). The molding parameters used are summarized in Table 1.

TABLE 1 Barrel Temperature (° C.), feed Section 215.5 Barrel Temperature(° C.), Trans. Section 237.8 Barrel Temperature (° C.), Metering Section237.8 Barrel Temperature (° C.), Nozzle 237.8 Injection Time - High (s)6 Injection Time - Low (s) 23 Cooling Time (s) 30 Decompression Time (s)0.07 Clamp Open Time (s) 0.02 Mold Close Time (s) 60 Cycle Time (s) 62Screw Speed (rpm) 20 Injection rate Max Shot size (inch) 1.5 Cushion(inch) 0.2 Injection Pressure - High (psi) 5250 Injection Pressure - Low(psi) 5000 Back Pressure (psi) 1000 Clamp Pressure - High (psi) 1850Clamp Pressure - Low (psi) 1000 Mold Temperature (° C.), represented bycooling 11.7 water Cycle Auto

Examples of the polyethylene compositions were produced in a dualreactor solution polymerization process in which the contents of thefirst reactor flow into the second reactor. This in-series “dualreactor” process produces an “in-situ” polyethylene blend (i.e., thepolyethylene composition). Note, that when an in-series reactorconfiguration is used, un-reacted ethylene monomer, and un-reactedalpha-olefin comonomer present in the first reactor will flow into thedownstream second reactor for further polymerization.

In the present inventive examples, although no co-monomer is feeddirectly to the downstream second reactor, an ethylene copolymer isnevertheless formed in second reactor due to the significant presence ofun-reacted 1-octene flowing from the first reactor to the second reactorwhere it is copolymerized with ethylene. Each reactor is sufficientlyagitated to give conditions in which components are well mixed. Thevolume of the first reactor was 12 liters and the volume of the secondreactor was 22 liters. These are the pilot plant scales. The firstreactor was operated at a pressure of 10500 to 35000 kPa and the secondreactor was operated at a lower pressure to facilitate continuous flowfrom the first reactor to the second. The solvent employed wasmethylpentane. The process operates using continuous feed streams. Thecatalyst employed in the dual reactor solution process experiments was aphosphinimine catalyst, which was a titanium complex having aphosphinimine ligand (e.g., (tert-butyl)₃P=N), a cyclopentadienideligand (e.g., Cp) and two activatable ligands, such as but not limitedto chloride ligands (note: “activatable ligands” are removed, by forexample electrophilic abstraction using a co-catalyst or activator togenerate an active metal center). A boron based co-catalyst (e.g.,Ph₃CB(C₆F₅)₄) was used in approximately stoichiometric amounts relativeto the titanium complex. Commercially available methylaluminoxane (MAO)was included as a scavenger at an Al:Ti of about 40:1. In addition,2,6-di-tert-butylhydroxy-4-ethylbenzene was added to scavenge freetrimethylaluminum within the MAO in a ratio of Al:OH of about 0.5:1.

Comparative polyethylene compositions (Comparative Examples 1-3) aremade using a single site phosphinimine catalyst in a dual reactorsolution process in which all the comonomer is fed to the secondreactor.

Comparative polyethylene composition (Comparative Example 4) is aninjection molding grade believed to be an ethylene homopolymer made witha traditional polymerization catalyst (e.g., a Ziegler-Nattapolymerization catalyst) and which is commercially available from Ineosas J60-800-178.

Comparative polyethylene composition (Comparative Example 5) is aninjection molding grade polyethylene homopolymer, commercially availableresin from NOVA Chemicals as IG-454-A.

Comparative polyethylene compositions (Comparative Examples 6, 7 and 8)are made using a single site phosphinimine catalyst in a dual reactorsolution process according to U.S. Pat. No. 8,022,143 and CA Application2,752,407. Comparative resin 6 has a density of 0.952 g/cm³, a high loadmelt index I₂₁ of 71 g/10 min and a melt index ratio I₂₁/I₂ of 48.5.Comparative resin 7 has a density of 0.952 g/cm³ a high load melt indexI₂₁ of 71 g/10 min and a melt index ratio I₂₁/I₂ of 55. Comparativeresin 8 has a density of 0.953 g/cm³, a high load melt index I₂₁ of 80.2g/10 min and a melt index ratio I₂₁/I₂ of 64.4.

Inventive polyethylene compositions (Inventive Examples 1-6) are madeusing a single site phosphinimine catalyst in a dual reactor solutionprocess as described above and have an ESCR at condition B100 of greaterthan 3.5 hours and a SCB1/SCB2 ratio of greater than 1.0. Theseinventive examples also have a Mz value of less than 300,000.

The polymerization conditions used to make the inventive compositionsare provided in Table 2.

Inventive and comparative polyethylene composition properties aredescribed in Tables 3.

Calculated properties for the first ethylene copolymer and the secondethylene copolymer for selected comparative and inventive polyethylenecompositions are provided in Table 4 (see “Copolymerization ReactorModeling” below for methods).

The properties of pressed plaques made from comparative and inventivepolyethylene compositions are provided in Table 5.

Information on dimensional stability for inventive and comparativeresins is provided in Table 6.

Copolymerization Reactor Modeling

For multicomponent (or bimodal resins) polyethylene polymers with verylow comonomer content, it can be difficult to reliably estimate theshort chain branching (and subsequently polyethylene resin density bycombining other information) of each polymer component by mathematicaldeconvolution of GPC-FTIR data, as was done in, for example, U.S. Pat.No. 8,022,143. Instead, the M_(w), M_(n), M_(z), M_(w)/M_(n) and theshort chain branching per thousand carbons (SCB/1000C) of the first andsecond copolymers were calculated herein, by using a reactor modelsimulation using the input conditions which were employed for actualpilot scale run conditions (for references on relevant reactor modelingmethods, see “Copolymerization” by A. Hamielec, J. MacGregor, and A.Penlidis in Comprehensive Polymer Science and Supplements, volume 3,Chapter 2, page 17, Elsevier, 1996 and “Copolymerization of Olefins in aSeries of Continuous Stirred-Tank Slurry-Reactors using HeterogeneousZiegler-Natta and Metallocene Catalysts. I. General Dynamic MathemacialModel” by J. B. P Soares and A. E Hamielec in Polymer ReactionEngineering, 4(2&3), p 153, 1996.) This type of model is consideredreliable for the estimate of comonomer (e.g., 1-octene) content even atlow comonomer incorporation levels, since the ethylene conversion,ethylene input flow and comonomer input flow can be obtained directlyfrom the experimental conditions and because the reactive ratio (seebelow) can be reliably estimated for the catalyst system used in thepresent invention. For clarity, the “monomer” or “monomer 1” representethylene, while the terms “comonomer” or “monomer 2”, represent1-octene.

The model takes for input the flow of several reactive species (e.g.catalyst, monomer such as ethylene, comonomer such as 1-octene,hydrogen, and solvent) going to each reactor, the temperature (in eachreactor), and the conversion of monomer (in each reactor), andcalculates the polymer properties (of the polymer made in each reactor,i.e., the first and second ethylene copolymers) using a terminal kineticmodel for continuously stirred tank reactors (CSTRs) connected inseries. The “terminal kinetic model” assumes that the kinetics dependupon the monomer unit within the polymer chain on which the activecatalyst site is located (see “Copolymerization” by A. Hamielec, J.MacGregor, and A. Penlidis in Comprehensive Polymer Science andSupplements, Volume 3, Chapter 2, page 17, Elsevier, 1996). In themodel, the copolymer chains are assumed to be of reasonably largemolecular weight to ensure that the statistics of monomer/comonomer unitinsertion at the active catalyst center is valid and thatmonomers/comonomers consumed in routes other than propagation arenegligible. This is known as the “long chain” approximation.

The terminal kinetic model for polymerization includes reaction rateequations for activation, initiation, propagation, chain transfer, anddeactivation pathways. This model solves the steady-state conservationequations (e.g., the total mass balance and heat balance) for thereactive fluid which comprises the reactive species identified above.

The total mass balance for a generic CSTR with a given number of inletsand outlets is given by:0=Σ_(i) {dot over (m)} _(i)  (1)where {dot over (m)}_(i) represents the mass flow rate of individualstreams with index i indicating the inlet and outlet streams.

Equation (1) can be further expanded to show the individual species andreactions:

$\begin{matrix}{0 = {\frac{\Sigma_{i}\frac{m{\overset{.}{x}}_{ij}}{M_{i}}}{\rho_{mix}V} + {R_{j}/\rho_{mix}}}} & (2)\end{matrix}$where M_(i) is the average molar weight of the fluid inlet or outlet(i), x_(ij) is the mass fraction of species j in stream i, ρ_(mix) isthe molar density of the reactor mixture, V is the reactor volume, R_(j)is the reaction rate for species j, which has units of kmol/m³s.

The total heat balance is solved for an adiabatic reactor and is givenby:0=(Σ{dot over (m)} _(i) ΔH _(i) +q _(Rx) V+{dot over (W)}−{dot over(Q)})  (2)where, {dot over (m)}_(i) is the mass flow rate of stream i (inlet oroutlet), ΔH_(i) is the difference in enthalpy of stream i versus areference state, q_(Rx) is the heat released by reaction(s), V is thereactor volume, {dot over (W)} is the work input (i.e., agitator), {dotover (Q)} is the heat input/loss.

The catalyst concentration input to each reactor is adjusted to matchthe experimentally determined ethylene conversion and reactortemperature values in order solve the equations of the kinetic model(e.g., propagation rates, heat balance and mass balance).

The H₂ concentration input to each reactor may be likewise adjusted sothat the calculated molecular weight distribution of a polymer made overboth reactors (and, hence, the molecular weight of polymer made in eachreactor) matches that which is observed experimentally.

The degree of polymerization (DPN) for a polymerization reaction isgiven by the ratio of the rate of chain propagation reactions over therate of chain transfer/termination reactions:

$\begin{matrix}{{DPN} = \frac{{k_{p\; 11}{\phi_{1}\lbrack m_{1} \rbrack}} + {k_{p\; 12}{\phi_{1}\lbrack m_{2} \rbrack}} + {k_{p\; 21}{\phi_{2}\lbrack m_{2} \rbrack}}}{{{k_{{tm}\; 11}\lbrack m_{1} \rbrack}\phi_{1}} + {{k_{{tm}\; 12}\lbrack m_{2} \rbrack}\phi_{1}} + {{k_{{tm}\; 21}\lbrack m_{2} \rbrack}\phi_{2}} + {k_{{ts}\; 1}\phi_{1}} + {k_{{ts}\; 2}\phi_{2}} + {k_{{tH}\; 1}\lbrack H\rbrack} + {k_{{tH}\; 2}\lbrack H\rbrack}}} & (4)\end{matrix}$where k_(p12) is the propagation rate constant for adding monomer 2 to agrowing polymer chain ending with monomer 1, [m₁] is the molarconcentration of monomer 1 (ethylene) in the reactor, [m₂] is the molarconcentration of monomer 2 (1-octene) in the reactor, k_(tm12) thetermination rate constant for chain transfer to monomer 2 for a growingchain ending with monomer 1, k_(ts1) is rate constant for thespontaneous chain termination for a chain ending with monomer 1, k_(tH1)is the rate constant for the chain termination by hydrogen for a chainending with monomer 1. φ₁ and φ₂ and the fraction of catalyst sitesoccupied by a chain ending with monomer 1 or monomer 2 respectively.

The number average molecular weight (Mn) for a polymer follows from thedegree of polymerization and the molecular weight of a monomer unit.From the number average molecular weight of polymer in each reactor, andassuming a Flory distribution for a single site catalyst, the molecularweight distribution is determined for the polymer formed in eachreactor:w(n)=τ² ne ^(−τn)  (5)where

${\tau = \frac{1}{DPN}},$and w(n) is the weight fraction of polymer having a chain length n.

The Flory distribution can be transformed into the common log scaled GPCtrace by applying:

$\begin{matrix}{\frac{\mathbb{d}W}{\mathbb{d}{\log(M)}} = {{\ln(10)}\frac{n^{2}}{{DPN}^{2}}{\mathbb{e}}^{({- \frac{n}{DPN}})}}} & (6)\end{matrix}$where

$\frac{\mathbb{d}W}{\mathbb{d}{\log({MW})}}$is the differential weight fraction of polymer with a chain length n(n=MW/28 where 28 is the molecular weight of the polymer segmentcorresponding to a C₂H₄ unit) and DPN is the degree of polymerization ascalculated by Equation (4). From the Flory model, the M_(w) and theM_(z) of the polymer made in each reactor are: M_(w)=2×M_(n) andM_(z)=1.5×M_(w).

The overall molecular weight distribution over both reactors is simplythe sum of the molecular weight distribution of polymer made in eachreactor, and where each Flory distribution is multiplied by the weightfraction of polymer made in each reactor:

$\begin{matrix}{\frac{\mathbb{d}\overset{\_}{W}}{\mathbb{d}{\log({MW})}} = {{W_{R\; 1}( {{\ln(10)}\frac{n^{2}}{{DPN}_{R\; 1}^{2}}{\mathbb{e}}^{({- \frac{n}{{DPN}_{R\; 1}}})}} )} + {W_{R\; 2}( {{\ln(10)}\frac{n^{2}}{{DPN}_{R\; 2}^{2}}{\mathbb{e}}^{({- \frac{n}{{DPN}_{R\; 2}}})}} )}}} & (7)\end{matrix}$where dW/d log(MW) is the overall molecular weight distributionfunction, w_(R1) and W_(R2) are the weight fraction of polymer made ineach reactor, DPN₁ and DPN₂ is the average chain length of the polymermade in each reactor (i.e. DPN₁=M_(nR1)/28). The weight fraction ofmaterial made in each reactor is determined from knowing the mass flowof monomer and comonomer into each reactor along with knowing theconversions for monomer and comonomer in each reactor.

The moments of the overall molecular weight distribution (or themolecular weight distribution of polymer made in each reactor) can becalculated using equations 8a, 8b and 8c (a Flory Model is assumedabove, but the below generic formula apply to other model distributionsas well):

$\begin{matrix}{\overset{\_}{M_{n}} = \frac{\Sigma_{i}w_{i}}{\Sigma_{i}\frac{w_{i}}{M_{i}}}} & ( {8a} ) \\{\overset{\_}{M_{w}} = \frac{\Sigma_{i}w_{i}M_{i}}{\Sigma_{i}w_{i}}} & ( {8b} ) \\{\overset{\_}{M_{z}} = \frac{\Sigma_{i}w_{i}M_{i}^{2}}{\Sigma_{i}w_{i}M_{i}}} & ( {8c} )\end{matrix}$

The comonomer content in the polymer product (in each reactor) may alsobe calculated using the terminal kinetic model and long chainapproximations discussed above (see A. Hamielec, J. MacGregor, and A.Penlidis. Comprehensive Polymer Science and Supplements, volume 3,chapter Copolymerization, page 17, Elsevier, 1996).

For a given catalyst system, the comonomer (e.g., 1-octene)incorporation is a function of the monomer (e.g., ethylene) conversion,the comonomer to monomer ratio in the reactor (γ) and the reactivityratio of monomer 1 (e.g., ethylene) over monomer 2 (e.g., 1-octene):r ₁ =k _(p11) /k _(p12).

For a CSTR, the molar ratio of ethylene to comonomer in the polymer (γ)can be estimated knowing the reactivity ratio r₁ of the catalyst systemand knowing the ethylene conversion in the reactor (Q_(m1)). A quadraticequation can be derived using the May and Lewis equation forinstantaneous comonomer incorporation (see “Copolymerization” by A.Hamielec, J. MacGregor, and A. Penlidis in Comprehensive Polymer Scienceand Supplements, Volume 3, Chapter 2, page 17, Elsevier, 1996) andsolving the mass balance around the reaction. The molar ratio ofethylene to 1-octene in the polymer is the negative root of thefollowing quadratic equation:

$\begin{matrix}{{{{- Y^{2}}\frac{\gamma}{4}} + {\lbrack {r_{1} + {Q_{m\; 1}( {1 - r_{1}} )} + \frac{\gamma}{4}} \rbrack Y} - Q_{m\; 1}} = 0} & (9)\end{matrix}$where Y is the molar ratio of ethylene to 1-octene in the polymer, γ isthe mass flow ratio of 1-octene to ethylene going the reactor, r₁ is thereactivity ratio of monomer 1 to monomer 2 for the catalyst system(r₁=k_(p11)/k_(p12)) and Q_(m1) is the ethylene monomer fractionalconversion.

The branching frequency can then be calculated knowing the molar ratioof monomer 1 to monomer 2 in the polymer:

$\begin{matrix}{{BF} = \frac{500}{Y + 1}} & (10)\end{matrix}$where Y, is the molar ratio of monomer 1 (ethylene) over monomer 2(1-octene) in the polymer, and BF is the branching frequency (branchesper 1000 carbon atoms).

The overall branching frequency distribution (BFD) of the ethylenecomposition can be calculated by knowing the molecular weightdistribution and weight fraction of polymer made in each reactor, andthe average branching frequency (BF) of the ethylene copolymer made ineach reactor. The fraction of polymer made in each reactor can becalculated from the experimental mass flows and conversion of monomerand comonomer in each reactor. The branching frequency distributionfunction is obtained by calculating the average branch content for eachmolecular weight value of the overall molecular weight distributionfunction made from the two Flory distributions:

$\begin{matrix}{{BF}_{MW} = \frac{{w_{R\; 1}{BF}_{R\; 1}{F_{1}( {MW}_{R\; 1} )}} + {w_{R\; 2}{BF}_{R\; 2}{F_{2}( {MW}_{R\; 2} )}}}{{w_{R\; 1}{F_{1}( {MW}_{R\; 1} )}} + {w_{R\; 2}{F_{2}( {MW}_{R\; 2} )}}}} & (11)\end{matrix}$where BF_(MW) is the branching at molecular weight (MW), w_(R1) andw_(R2) are the weight fraction of polymer made in Reactor 1 and Reactor2, BF_(R1) and BF_(R2) are the average branching frequency of polymermade in R1 and R2 (from Equations 9 and 10), F₁(MW_(R1)) and F₂(MW_(R2))are Flory distribution function from Reactor 1 and Reactor 2.

The overall branching frequency of the polyethylene composition is givenby the weighted average of the branching frequency of the polymer madein each reactor:BF _(avg) =w ₁ BF ₁ +w ₂ BF ₂  (12)where, BF_(avg) is the average branching frequency for the total polymer(e.g. the polyethylene composition), w₁ and w₂ are the weight fractionof material made in each reactor, BF₁ and BF₂ are the branchingfrequency of material made in each reactor (e.g., the branchingfrequency of the first and second ethylene copolymers).

For the polymer obtained in each reactor, the key resin parameters whichare obtained from the above described kinetic model are the molecularweights Mn, Mw and Mz, the molecular weight distributions M_(w)/M_(n)and Mz/Mw and the branching frequency (SCB/1000 Cs). With thisinformation in hand, a component (or composition) density model and acomponent (or composition) melt index, I₂, model was used according tothe following equations, which were empirically determined, to calculatethe density and melt index I₂ of each of the first and second ethylenecopolymers:

Density:

$\frac{1}{\rho} = {1.0142 + {0.0033( {1.22 \cdot {BF}} )^{0.8346}} + \frac{0.030\; k^{0.9804}}{1 + \frac{0.3712}{{\mathbb{e}}^{1.22\;{BF}}}}}$where, BF is the branching frequency,

$k = {{Log}_{10}( \frac{M_{n}}{1000} )}$Melt Index, I₂ (MI):

${{Log}_{10}({MI})} = {7.8998 - {3.9089\;{{Log}_{10}( \frac{M_{w}}{1000} )}} - {0.2799\frac{M_{n}}{M_{w}}}}$

Hence, the above models were used to estimate the branch frequency,weight fraction (or weight percent), melt index and the density of thepolyethylene composition components, which were formed in each ofreactor 1 and 2 (i.e. the first and second ethylene copolymers).

TABLE 2 Reactor Conditions for Inventive Examples Inventive InventiveInventive Inventive Inventive Inventive Example No. Example #1 Example#2 Example #3 Example #4 Example #5 Example #6 Material Name PS 101801PS 103550 PS 103562 PS 103574 PS 103584 PS104136 Reactor 1 Ethylene(kg/h) 40.4 35.7 35.6 35.6 35.7 24.5 Octene (kg/h) 1.7 1.5 1.9 1.4 2 0.6Hydrogen (g/h) 1.04 0.7 0.6 0.6 0.7 0.4 Solvent (kg/h) 282 252.8 252.5253.1 252.3 171 Reactor feed inlet 30 30 30 30 30 30 temperature (° C.)Reactor Temperature 163 162.3 162 161.7 162 162 (° C.) Catalyst (ppm)0.1 0.11 0.12 0.12 0.14 0.12 Reactor 2 Ethylene (kg/h) 40.4 43.6 43.643.5 43.5 57 Octene (kg/h) 0 0 0 0 0 0 Hydrogen (g/h) 14.30 13.90 19.2011.50 14.30 6.6 Solvent (kg/h) 102 132 131 131 131 222 Reactor feedinlet 30 30 30 30 30 30 temperature (° C.) Reactor Temperature 205 202202 202 202 203 (° C.) Catalyst (ppm) 0.72 0.56 0.59 0.56 0.57 0.42

TABLE 3 Resin Properties Resin Inv. Ex. 1 Inv. Ex. 2 Inv. Ex. 3 Inv. Ex.4 Inv. Ex. 5 Inv. Ex. 6 Material Name PS PS PS PS PS PS 101801 103550103562 103574 103584 104136 Density (g/cm³) 0.9569 0.955 0.9575 0.95590.9555 0.9555 Rheology/Flow Properties Melt Index I₂ 7.66 7.21 7.29 4.547.17 8.1 (g/10 min) I₅ 21.9 13.2 23.5 I₂₁ 239 237 312 171 268 228 MeltFlow Ratio (I₂₁/I₂) 31.2 32.8 42.8 37.8 37.4 28.9 Stress Exponent 1.281.31 1.35 1.32 1.33 1.32 Shear Viscosity (η) at 10⁵ 5.9 6.3 4.8 6.2 5.66.9 s⁻¹ (240° C., Pa-s) 100/η at 10⁵ s⁻¹ (240° C.), 16.95 15.87 20.8316.13 17.86 14.49 Processability Indicator Shear viscosity Ratio 66.460.9 79.6 84.5 70 51.78 (η100/η100000, 240° C.) GPC M_(n) 13088 1612711001 16505 14020 23319 M_(w) 61162 59330 57976 68596 58484 63204 M_(z)153222 144200 163371 187835 149424 148799 Polydispersity Index 4.67 3.685.27 4.16 4.17 2.71 (M_(w)/M_(n)) TREF CDBI(50) 71.1 80.3 72 79.5 7878.9 CDBI(25) 59.5 70.6 62.4 68.1 68.7 67.2 Branch Frequency-FTIR(uncorrected for chain end —CH₃) Uncorrected SCB/1000C 1.7 1.4 2.1 1.51.8 0.9 Uncorrected comonomer 0.3 0.3 0.4 0.3 0.4 0.2 content (mol %)Comonomer ID 1-octene 1-octene 1-octene 1-octene 1-octene 1-octeneTerminal 0.21 0.08 0.09 0.09 0.08 0.12 unsaturation/1000C Internal 0.090.16 0.13 0.14 0.14 0.11 unsaturation/1000C Side chain 0 0.01 0.01 0.000.01 0 unsaturation/1000C Total unsaturations/1000C 0.30 0.25 0.23 0.230.23 0.23 Comonomer mol % measured by ¹³C-NMR Hexyl+ branches 0.29 0.31(>=4 C atoms), mol % DSC Primary Melting Peak (° C.) 129.77 129.72129.71 130.0 129.46 131.5 Heat of Fusion (J/g) 217.6 214.2 218.8 216.4215.7 215.6 Crystallinity (%) 75.04 73.88 75.44 74.63 74.37 74.33 HexaneExtractables (%) 0.33 Resin Comp. Ex. 1 Comp. Ex. 2 Comp. Ex. 3 Comp.Ex. 4 Comp. Ex. 5 Material Name PS 101778 PS 101787 PS 101793J60-800-178 IG454-A Density (g/cm³) 0.9584 0.9585 0.9591 0.960 0.9540Rheology/Flow Properties Melt Index I₂ (g/10 min) 7.18 7.51 8.56 8.529.00 I₅ I₂₁ 229 234 258 222 191 Melt Flow Ratio (I₂₁/I₂) 32 31.2 30.126.1 21.2 Stress Exponent 1.28 1.27 1.26 1.29 1.22 Shear Viscosity (η)at 10⁵ 5.8 5.7 6.9 7.9 s⁻¹ (240° C., Pa-s) 100/η at 10⁵ s⁻¹ (240° C.),17.24 17.54 14.49 12.66 Processability Indicator Shear viscosity Ratio54.6 47.9 (η100/η100000, 240° C.) GPC M_(n) 14526 13771 13469 1702220519 M_(w) 64533 62612 59226 63567 59812 M_(z) 166380 157914 144926181472 140168 Polydispersity Index 4.44 4.55 4.40 3.73 2.91(M_(w)/M_(n)) TREF CDBI(50) 46.6 45.2 — 68.5 74.6 CDBI(25) 32.4 29.4 —53.6 50.7 Branch Frequency- FTIR (uncorrected for chain end —CH₃)Uncorrected SCB/1000C 2.0 2 1.0 Uncorrected comonomer 0.4 0.4 <0.1 0.2content (mol %) Comonomer ID 1-octene 1-octene 1-octene 1-butene1-octene Terminal 0.16 0.12 0.14 0.17 0.50 unsaturation/1000C Internal0.08 0.09 0.08 0.04 0 unsaturation/1000C Side chain 0.01 0.01 0.01 00.01 unsaturation/1000C Total unsaturations/1000C 0.25 0.22 0.23 0.210.51 Total unsaturations per 0.26 0.22 0.22 0.26 0.75 number averagemolecule Comonomer mol % measured by ¹³C-NMR Hexyl+ branches(<=4 — — — —— carbon atoms), mol % DSC Primary Melting Peak (° C.) 130.79 130.02132.3 130.8 Heat of Fusion (J/g) 220.9 220.3 217.9 208.7 Crystallinity(%) 76.17 75.96 75.14 72.0 Hexane Extractables (%) 0.44 0.38 0.37

TABLE 4 Polyethylene Component Properties Resin Inv. Ex. 1 Inv. Ex. 2Inv. Ex. 3 Inv. Ex. 4 Inv. Ex. 5 Inv. Ex. 6 Sample Name PS PS PS PS PSPS 101801 103550 103562 103574 103584 104136 Density (g/cm³) 0.95690.955 0.9575 0.9559 0.9555 0.9559 I₂ (g/10 min.) 7.66 7.21 7.29 4.547.17 8.2 Stress Exponent 1.28 1.31 1.35 1.32 1.33 1.31 MFR (I₂₁/I₂) 31.232.8 42.8 37.8 37.4 28.6 Mw/Mn 4.67 3.68 5.27 4.16 4.17 2.71 FirstEthylene Polymer Weight fraction 0.5 0.48 0.48 0.47 0.47 0.32 Mw 107939101355 109586 117645 105809 125184 I₂ (g/10 min.) 0.65 0.83 0.61 0.460.70 0.36 Density, d1 (g/cm³) 0.9421 0.9414 0.9395 0.9420 0.9402 0.9426SCB1/1000C 0.66 0.8 0.93 0.59 0.88 0.48 Second Ethylene Polymer Weightfraction 0.5 0.52 0.52 0.53 0.53 0.68 Mw 15056 19854 12425 19110 1590332391 I₂ (g/10 min.) 1433 486 3036 564 1157 72 Density, d2 (g/cm³)0.9630 0.9615 0.9653 0.9621 0.9626 0.9593 SCB2/1000C 0.49 0.34 0.43 0.310.47 0.111 Estimated (d2-d1), g/cm³ 0.021 0.020 0.026 0.020 0.022 0.017Estimated SCB1/SCB2 1.35 2.35 2.16 1.90 1.87 4.32 Resin Comp. Ex. 1Comp. Ex. 2 Comp. Ex. 3 Sample Name PS 101788 PS 101787 PS 101793Density (g/cm³) 0.9584 0.9585 0.9591 I₂ (g/10min.) 7.18 7.51 8.56 StressExponent 1.28 1.27 1.26 MFR (I₂₁/I₂) 32 31.2 30.1 Mw/Mn 4.44 4.55 4.4First Ethylene Polymer Weight fraction 0.5 0.5 0.5 Mw 110512 108978103442 I₂ (g/10 min.) 0.59 0.63 0.77 Density, dl (g/cm3) 0.9503 0.95040.9509 SCB1/1000C 0 0 0 Second Ethylene Polymer Weight fraction 0.5 0.50.5 Mw 14593 14618 14581 I₂ (g/10 min.) 1619 1608 1625 Density, d2(g/cm³) 0.9552 0.9553 0.9553 SCB2/1000C 2.1 2.07 2.07 Estimated (d2-d1),g/cm³ 0.005 0.005 0.004 Estimated SCB1/SCB2 0.00 0.00 0.00

TABLE 5 Plaque Properties Resin Inv. Ex. 1 Inv. Ex. 2 Inv. Ex. 3 Inv.Ex. 4 Inv. Ex. 5 Environmental Stress Crack Resistance ESCR Cond. B at100% (hrs.) 4 5 6 7 5 Flexural Properties (Plaques) Flex Secant Mod. 1%(MPa) 1352 1369 1460 1352 1308 Flex Sec Mod 1% (MPa) Dev. 58 37 33 76 51Flex Secant Mod. 2% (MPa) 1135 1151 1245 1152 1114 Flex Sec Mod 2% (MPa)Dev. 35 18 17 52 34 Flexural Strength (MPa) 39.5 40.1 42.5 40.2 39.2Flexural Strength Dev. (MPa) 0.4 0.4 0.5 1.1 0.7 Tensile Properties(Plaques) Elong. at Yield (%) 8 9 8 9 8 Elong. at Yield Dev. (%) 0 0 1 00 Yield Strength (MPa) 28.2 29.6 31 29.8 29.8 Yield Strength Dev. (MPa)0.8 0.2 0.1 0.2 0.2 Ultimate Elong. (%) 1018 1033 491 1042 995 UltimateElong. Dev. (%) 39 36 523 105 32 Ultimate Strength (MPa) 18.8 18.8 2023.4 19.1 Ultimate Strength Dev. (MPa) 0.8 0.9 4.7 4.4 0.6 Sec Mod 1%(MPa) 1702 1372 1644 1505 1531 Sec Mod 1% (MPa) Dev. 222 81 143 94 111Sec Mod 2% (MPa) 1077 1022 1135 1069 1065 Sec Mod 2% (MPa) Dev. 67 47 5737 19 Impact Properties (Plaques) Notched Izod Impact (ft-lb/in) 0.8 0.90.8 1 0.9 Notched Izod Impact (J/m) 42.72 48.06 42.72 53.4 48.06 ResinComp. Ex. 1 Comp. Ex. 2 Comp. Ex. 3 Comp. Ex. 4 Comp. Ex. 5Environmental Stress Crack Resistance ESCR Cond. B at 100% (hrs.) 1 1 15 5 Flexural Properties (Plaques) Flex Secant Mod. 1% (MPa) 1349 13741280 Flex Sec Mod 1% (MPa) Dev. 65 49 62 Flex Secant Mod. 2% (MPa) 11421149 1083 Flex Sec Mod 2% (MPa) Dev. 43 33 50 Flexural Strength (MPa)40.4 40.6 37.9 Flexural Strength Dev. (MPa) 0.7 0.6 1 Tensile Properties(Plaques) Elong. at Yield (%) 9 8 10 Elong. at Yield Dev. (%) 0 1 1Yield Strength (MPa) 29 29.1 27.9 Yield Strength Dev. (MPa) 0.4 0.3 0.5Ultimate Elong. (%) 450 11 1433 (very brittle failure) Ultimate Elong.Dev. (%) 165 1 200 Ultimate Strength (MPa) 14.8 29.1 23.9 (very brittlefailure) Ultimate Strength Dev. (MPa) 0.9 0.3 3.7 Sec Mod 1% (MPa) 17281405 1263 Sec Mod 1% (MPa) Dev. 292 359 404 Sec Mod 2% (MPa) 1106 1038904 Sec Mod 2% (MPa) Dev. 69 102 116 Impact Properties (Plaques) NotchedIzod Impact (ft-lb/in) 0.6 0.6 1 Notched Izod Impact (J/m) 32.04 32.0453.4

TABLE 6 Dimensional Stability Resin Inv. Ex. 1 Inv. Ex. 2 Inv. Ex 3 Inv.Ex. 4 Inv. Ex. 5 Inv. Ex. 6 TD shrinkage, IM disk, 48 hr. 1.67 1.87 1.931.71 1.79 1.84 MD shrinkage, IM disk, 48 hr. 1.62 1.72 1.93 1.77 1.771.89 (TD shrinkage-MD shrinkage), IM disk, 48 hr. 0.05 0.15 0 −0.06 0.02−0.05 TD/MD shrinkage ratio, isotropy indicator, IM disk, 48 hr. 1.031.09 1.00 0.97 1.09 0.97 Resin Comp. Ex. 4 Comp. Ex. 5 Com. Ex. 6 Comp.Ex. 7 Comp. Ex.8 TD shrinkage, IM disk, 48 hr. 1.82 1.69 1.79 1.77 1.89MD shrinkage, IM disk, 48 hr. 1.68 1.31 1.98 2.17 2.17 (TD shrinkage-MDshrinkage), 0.14 0.38 −0.19 −0.40 −0.28 IM disk, 48 hr. TD/MD shrinkageratio, isotropy 1.08 1.29 0.90 0.82 0.87 indicator, IM disk, 48 hr.

As can be seen from the data provided in Tables 3-6 and FIGS. 1-3, theinventive polyethylene compositions have very good dimensionalstability, are easy to process (e.g., have good injectability whenmaking an injection molded part), show good organoleptic properties andimpact resistance and have useful ESCR for applications such as waterbottle closures. For example, FIG. 1 shows that relative to comparativeexamples 1, 2, 4 (J60-800-178) and 5 (IG454-A), the inventivecompositions 1-5 have an improved balance of processability and ESCR.Also, as shown in FIG. 2, the inventive compositions 1-5 have a betterbalance of processability and impact strength when compared tocomparative resins 1, 2, 4 (J60-800-178) and 5 (IG454-A). Theprocessability comparison is made on the basis of a “processabilityindicator” which in the present invention is defined as 100/η at 10⁵ s⁻¹(240° C.), where η is the Shear Viscosity (η) at 10⁵ s⁻¹ (240° C., Pa-s)as defined above.

FIG. 3 shows that the inventive compositions 1 and 2 have a betterdimensional stability (the TD/MD shrinkage isotropy indicator) than apolypropylene homopolymer having a melt flow rate of 35 g/10 min (testedat 230° C. under 2.16 kg). Inventive compositions 1 and 2 havecomparable or better dimensional stability than comparative examples 4(J60-800-178) and 5 (IG454-A).

Table 6 shows that inventive polyethylene compositions 1-6 generallyhave better dimensional stability than comparative resins 4-8. Compare,for example, inv. compositions 1, 2, 3, 4, 5 and 6 which have a TDshrinkage-MD shrinkage of 0.05, 0.15, 0, −0.06, 0.02, and −0.05respectively with comp. resins 4, 5, 6, 7, and 8 which have a TDshrinkage-MD shrinkage of 0.14, 0.38, −0.19, −0.40, −0.28 respectively.Also compare the TD/MD shrinkage ratio (the indicator of isotropy) forinventive compositions 1, 2, 3, 4, 5 and 6 at 1.03, 1.09, 1, 0.97, 1.09and 0.97 respectively which are all fairly close to 1, with the TD/MDshrinkage ratio (the indicator of isotropy) for comp. compositions 4, 5,6, 7, and 8 which are 1.08, 1.29, 0.90, 0.82, and 0.87, respectively.

FIGS. 4A and 4B compare the composition distribution breadth indexCDBI(50) of inventive example 1 with comparative example 2 as determinedby temperature elution rising fractionation (TREF). Comparative example2 shows three peaks in the TREF profile and has a CDBI(50) of 45.2weight percent (wt %). Inventive example 1 shows a single dominant peakin the TREF profile and has a CDBI(50) of greater than 70 wt %. Hence,inventive example 1 has a more uniform composition distribution, whichis thought to increase polymer toughness (e.g., impact resistance).

Further, inventive resin 1, indeed all the inventive compositions haverelatively high CDBI(25) values (see Table 3). Compare for example theTREF analysis of inventive resin 1 (CDBI(25)=59.5%) with comparativeresin 2 (CDBI(25)=29.4%) as shown in FIGS. 4A and 4B. Also see the datain Table 3 where inventive resins 1-6 all have a CDBI(25) of greaterthan 59% by weight, while comparative resins 1, 2, 4 and 5 all haveCDBI(25) values of less than about 54% by weight. Indeed, comparativeresins 1 and 2 have CDBI(25) values of less than 35% by weight.

The polyethylene compositions of the present invention can be used indrinkable water, juice, hot fill applications or other non-pressurizedcaps and closures applications.

The present invention has been described with reference to certaindetails of particular embodiments thereof. It is not intended that suchdetails be regarded as limitations upon the scope of the inventionexcept insofar as and to the extent that they are included in theaccompanying claims.

What is claimed is:
 1. A closure for bottles, the closure comprising apolyethylene composition, the polyethylene composition comprising: (1)about 10 to about 70 wt % of a first ethylene copolymer having a meltindex I₂, of from 0.1 to 10 g/10 min; a molecular weight distributionM_(w)/M_(n), of less than 3.0; and a density of from 0.930 to 0.960g/cm³; and (2) about 90 to about 30 wt % of a second ethylene copolymerhaving a melt index I₂, of from 50 to 10,000 g/10 min; a molecularweight distribution M_(w)/M_(n), of less than 3.0; and a density higherthan the density of the first ethylene copolymer, but less than 0.966g/cm³; wherein the density of the second ethylene copolymer is less than0.037 g/cm³ higher than the density of the first ethylene copolymer; theratio (SCB1/SCB2) of the number of short chain branches per thousandcarbon atoms in the first ethylene copolymer (SCB1) to the number ofshort chain branches per thousand carbon atoms in the second ethylenecopolymer (SCB2) is greater than 1.0; and wherein the polyethylenecomposition has a molecular weight distribution M_(w)/M_(n), of from 2to 7; a density of at least 0.950 g/cm³; a high load melt index I₂₁, offrom 150 to 400 g/10 min; a Z-average molecular weight M_(z), of lessthan about 300,000; a melt flow ratio I₂₁/I₂, of from 22 to 50; a stressexponent of less than 1.40; and an ESCR Condition B (100% IGEPAL) of atleast about 3.5 hrs; and wherein the closure is a hinged closure.
 2. Theclosure of claim 1 wherein the polyethylene composition has a TD/MDshrinkage ratio of from about 0.90 to about 1.15 when measured accordingto the Dimensional Stability Test (DST).
 3. The closure of claim 1wherein the polyethylene composition has an ESCR Condition B (100%IGEPAL) of from about 3.5 to about 15 hrs.
 4. The closure of claim 1wherein the polyethylene composition has a melt index I₂, of greaterthan 5.0 to less than 20 g/10 min.
 5. The closure of claim 1 wherein thefirst and second ethylene copolymers are made by polymerizing ethyleneand an alpha olefin in the presence of a single site catalyst.
 6. Theclosure of claim 1 wherein the density of the second ethylene copolymeris less than 0.030 g/cm³ higher than the density of the first ethylenecopolymer.
 7. The closure of claim 1 wherein the first ethylenecopolymer has a melt index I₂, of from 0.1 to 3.0 g/10 min.
 8. Theclosure of claim 1 wherein the second ethylene copolymer has a meltindex I₂, of from 100 to 5000 g/10 min.
 9. The closure of claim 1wherein the polyethylene composition has a melt index I₂, of from 6 to12 g/10 min.
 10. The closure of claim 1 wherein the polyethylenecomposition has a bimodal molecular weight distribution as determined bygel permeation chromatography.
 11. The closure of claim 1 wherein theratio (SCB1/SCB2) of the number of short chain branches per thousandcarbon atoms in the first ethylene copolymer (SCB1) to the number ofshort chain branches per thousand carbon atoms in the second ethylenecopolymer (SCB2) is at least 1.5.
 12. The closure of claim 1 wherein thepolyethylene composition has a molecular weight distributionM_(w)/M_(n), of from 3.5 to
 6. 13. The closure of claim 1 wherein thefirst ethylene copolymer has a density of from 0.936 to 0.952 g/cm³. 14.The closure of claim 1 wherein the second ethylene copolymer has adensity of less than 0.965 g/cm³.
 15. The closure of claim 1 wherein thepolyethylene composition has a density of from 0.952 to 0.960 g/cm³. 16.The closure of claim 1 wherein the polyethylene composition has no longchain branching.
 17. The closure of claim 1 wherein the first and secondethylene copolymers have a M_(w)/M_(n) of less than 2.5.
 18. The closureof claim 1 wherein the polyethylene composition has a compositiondistribution breadth index (CDBI(50)) of greater than about 65 wt %. 19.The closure of claim 1 wherein the first and second ethylene copolymerseach have a composition distribution breadth index (CDBI(50)) of greaterthan about 65 wt %.
 20. The closure of claim 1 wherein the polyethylenecomposition comprises: from about 25 to about 60 wt % of the firstethylene copolymer; and from about 75 to about 40 wt % of the secondethylene copolymer.
 21. The closure of claim 1 wherein the polyethylenecomposition has a comonomer content of less than about 0.5 mol % asdetermined by ¹³C NMR.
 22. The closure of claim 1 wherein thepolyethylene composition further comprises a nucleating agent or acombination of nucleating agents.
 23. The closure of claim 1 wherein thefirst and second ethylene copolymers are copolymers of ethylene and1-octene.
 24. The closure of claim 1 wherein the closure is made bycompression molding or injection molding.
 25. The closure of claim 1wherein the closure is a screw cap.
 26. The closure of claim 1 whereinthe polyethylene composition is prepared by contacting ethylene and analpha-olefin with a single site polymerization catalyst under solutionpolymerization conditions in a least two polymerization reactors.
 27. Aprocess for preparing a closure for bottles wherein the processcomprises at least one compression molding or injection molding step andwherein the closure comprises a polyethylene composition, thepolyethylene composition comprising: (1) about 10 to about 70 wt % of afirst ethylene copolymer having a melt index I₂, of from 0.1 to 10 g/10min; a molecular weight distribution M_(w)/M_(n), of less than 3.0; anda density of from 0.930 to 0.960 g/cm³; and (2) about 90 to about 30 wt% of a second ethylene copolymer having a melt index I₂, of from 50 to10,000 g/10 min; a molecular weight distribution M_(w)/M_(n), of lessthan 3.0; and a density higher than the density of the first ethylenecopolymer, but less than 0.966 g/cm³; wherein the density of the secondethylene copolymer is less than 0.037 g/cm³ higher than the density ofthe first ethylene copolymer; the ratio (SCB1/SCB2) of the number ofshort chain branches per thousand carbon atoms in the first ethylenecopolymer (SCB1) to the number of short chain branches per thousandcarbon atoms in the second ethylene copolymer (SCB2) is greater than1.0; and wherein the polyethylene composition has a molecular weightdistribution M_(w)/M_(n), of from 2 to 7; a density of at least 0.950g/cm³; a high load melt index I₂₁, of from 150 to 400 g/10 min; aZ-average molecular weight M_(Z), of less than about 300,000; a meltflow ratio I₂₁/I₂, of from 22 to 50; a stress exponent of less than1.40; and an ESCR Condition B (100% IGEPAL) of at least about 3.5 hrs;and wherein the closure is a hinged closure.